Electric Start Handbook

UNCLASSIFIED
Commercial In Confidence
Handbook for the Electric Start System for the Industrial Trent 60 and RB211 Gas Turbines
Ultra Electronics, PMES

Towers Business Park, Wheelhouse Road, Rugeley, Staffordshire WS15 1UZ, UK
Telephone: +44 (0)1889 503300 Fax: +44 (0) 1889 572929
Email: [email protected]
Doc No. 1003795

HANDBOOK
FOR THE
ELECTRIC START SYSTEM
FOR THE INDUSTRIAL
TRENT 60 AND RB211 GAS TURBINES
UNCONTROLLED
IF
PRINTED
First used on Contract: W2189
Written by: GFOSTER
Date: 20 Apr 2010
COPYRIGHT NOTICE
© Ultra Electronics, PMES 2009
This document and the data it records are provided in confidence and except with Ultra Electronics, PMES's prior written
consent, must not be copied in whole in any form, used for any purpose or disclosed to any person and all rights
(including copyright and design rights) therein belong to Ultra Electronics, PMES.
Doc No. 1003795 Commercial In Confidence

Rev: B, 20 Apr 2010 UNCLASSIFIED Page i
UNCLASSIFIED
CHANGE RECORD
R STATUS DATE APPROVAL COMMENTS

E
V
A Original 05 Oct 2009 Sent to RRC for initial comment. This is not a
formal issue
B Update 20 Apr 2010
APPROVAL RECORD
This document is approved by (see ECO/CN for signatures):
POSITION NAME POSITION NAME
Author G Foster Project Manager A Tunstall

Engineering Manager P Walker
DISTRIBUTION
Paper
1.
Electronic (will be notified on change)
POSITION NAME POSITION NAME
Commercial In Confidence Doc No. 1003795

Page ii UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
PREFACE
1 This handbook is for use with the production Electric Start System.
2 Handbook DR12743 provides instructions for the Prototype Electric Start System supplied to Rolls
Royce Canada
3 The operator information provided is limited to basic equipment on/off actions, and does not include
detailed system operating procedures.
4 For detailed drawing information, reference should be made to the latest issued Circuit Diagrams and
General Assembly drawings.

Rev: B, 20 Apr 2010 UNCLASSIFIED Page iii
UNCLASSIFIED
CONTENTS
Page
PRELIMINARY MATERIAL
Front cover (title page) ................................................................................................................................ i

Change record ............................................................................................................................................ ii
Approval record ............................................................................................................................................. ii
Distribution .................................................................................................................................................. ii
Preface ..................................................................................................................................................iii
Contents (this list) ....................................................................................................................................... iv
List of abbreviations ................................................................................................................................... v
Glossary of terms ......................................................................................................................................... vi
Associated publications .............................................................................................................................vii
Warnings ............................................................................................................................................ viii-ix
Chapter 1 Purpose and Planning Information

Chapter 2 Operating Information
Chapter 3 Technical Description
Chapter 4 Installation Specification
Chapter 5 Maintenance Instructions
Chapter 6 Maintenance Schedules
Chapter 7 Parts Catalogue

Page iv UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
LIST OF ABBREVIATIONS
ACH Anti Condensation Heater

ASIC Application Specific Integrated Circuit
EMC Electro Magnetic Compatibility
ESC Electric Start Controller
ESM Electric Start Motor
ESS Electric Start System
GT Gas Turbine
GTES Gas Turbine Engineering Specification
Hz Hertz
IGBT Insulated Gate Bipolar Transistor
I/O Input/Output
IPT Inter Phase Transformer
JB Junction Box
LED light emitting diode
LRU line replaceable unit
MTBF Mean Time Between Failure
MTBO Mean Time Between Overhaul
NC Normally Closed
NO Normally Open
PEC panel electronic circuit
PWM Pulse Width Modulation
UK United Kingdom

Rev: B, 20 Apr 2010 UNCLASSIFIED Page v
UNCLASSIFIED
GLOSSARY OF TERMS
DeviceNet DeviceNet is a communication protocol used in the automation industry to interconnect

control devices for data exchange.

Page vi UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
ASSOCIATED PUBLICATIONS
PUBLICATION TITLE REF No.

Electric Start System Requirements GTES 10579
Vacon User’s Manual NX Inverters FI9-FI14

Rev: B, 20 Apr 2010 UNCLASSIFIED Page vii
UNCLASSIFIED
WARNINGS
HAZARDOUS SUBSTANCES
The equipment does not contain any hazardous materials that require controlling under UK COSHH
(Control of Substances Hazardous to Health) regulations.
WARNINGS
(1) ELECTRICAL ISOLATION. THE ELECTRIC START SYSTEM EQUIPMENT DOES NOT
INCLUDE FACILITIES FOR ISOLATION OR FUSING OF THE INCOMING THREE-PHASE
MAINS SUPPLY. THESE FACILITIES MUST BE SUPPLIED BY ROLLS-ROYCE.
INCLUDE FACILITIES FOR ISOLATION OR FUSING OF THE INCOMING SINGLE PHASE ACH
SUPPLY. THESE FACILITIES MUST BE SUPPLIED BY ROLLS-ROYCE.
(3) EMERGENCY STOP. THE ELECTRIC START SYSTEM IS NOT FITTED WITH AN
EMERGENCY STOP FACILITY. THIS FACILITY MUST BE SUPPLIED BY ROLLS-ROYCE.
(4) OIL SPILLAGE. DISCONNECTING THE OIL INLET AND OIL OUTLET PIPES WILL
CAUSE OIL SPILLAGE. ENSURE THAT AN OIL SPILL KIT IS AVAILABLE DURING THIS
PROCEDURE.
(5) EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START MOTOR IS 111KG.
(6) EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START CONTROLLER IS

1300 KG.
(7) EXCESSIVE WEIGHT. THE WEIGHT OF THE CONTROLLER DRIVE MODULE IS 100KG.
(8) EXCESSIVE WEIGHT. THE WEIGHT OF THE JUNCTION BOX IS 36 KG.
(9) EXCESSIVE WEIGHT. THE WEIGHT OF THE ESM CABLE ASSEMBLY IS 3.3KG/M.
(10) LETHAL VOLTAGE. THE EQUIPMENT EARTH STRAPS MUST BE SECURELY

ATTACHED TO ALL UNITS.
(11) LETHAL VOLTAGE. SUPPLY VOLTAGES USED IN THIS EQUIPMENT ARE

POTENTIALLY LETHAL. ENSURE ALL SUPPLIES ARE ISOLATED AT EXTERNAL
ISOLATORS BEFORE CARRYING OUT REMEDIAL ACTION. TAG OUT SYSTEM SHOULD BE
EMPLOYED.
(12) LETHAL VOLTAGE. WAIT FIVE MINUTES BEFORE OPENING ELECTRIC START
CONTROLLER DOORS.
(13) LETHAL VOLTAGE. WAIT FIVE MINUTES BEFORE REMOVING ELECTRIC START
CONTROLLER AIR VENTS.
(14) EXCESSIVE HEAT. THE SURFACES OF THE ESM MAY BE HOT. ALLOW FOUR
MINUTES OF NON-OPERATION WITH THE OIL SUPPLY ON BEFORE TOUCHING ESM.
(15) EXCESSIVE HEAT. THE SURFACES OF THE OIL SUPPLY PIPING MAY BE HOT.
ALLOW FOUR MINUTES OF NON-OPERATION WITH THE OIL SUPPLY ON BEFORE
TOUCHING OIL SUPPLY PIPING.

Page viii UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
(16) EARTH CONNECTION. UNDER NO CIRCUMSTANCES SHOULD THE EARTH

ARRANGEMENTS OR THE EQUIPMENT BE DISCONNECTED FROM EARTH BEFORE ALL
POWER SUPPLIES ARE ISOLATED AT SOURCE. TAG OUT SYSTEM SHOULD BE
EMPLOYED.
(17) ENCLOSURE RATING. THE MOTOR IP56 ENCLOSURE RATING IS ONLY ACHIEVED
WITH THE REAR TERMINATION COWL FITTED.
(18) ENCLOSURE RATING. THE CONTROLLER IP52 ENCLOSURE RATING IS ONLY

ACHIEVED WITH THE WEATHER STRIP FITTED ON THE DOORS.
(19) CONDENSATION. THE ACH SUPPLY SHOULD BE APPLIED TO THE ESC AT ALL
TIMES

Rev: B, 20 Apr 2010 UNCLASSIFIED Page ix
UNCLASSIFIED
CAUTIONS
CAUTIONS
(1) EQUIPMENT DAMAGE. Do not over tighten assembly as damage to the motor may
occur.
(2) EQUIPMENT DAMAGE. ESM Power Cables are subject to a minimum bend radius of
ten times the outside diameter of the cable.
(3) EQUIPMENT DAMAGE. Ensure the M12 crimped power cores are fitted using the
installation aid. If fitted incorrectly shorting to the cowl may occur.
(4) EQUIPMENT DAMAGE. Ensure there is a minimum clearance of 13 mm between

adjacent terminals as shorting between terminals may occur.
(5) EQUIPMENT DAMAGE. Connecting the swinging link to an incorrect input voltage tap
may result in excessive voltage and subsequent damage to the equipment.
(6) EQUIPMENT DAMAGE. Connecting the ACH supply in an incorrect input voltage
configuration may result in excessive voltage and subsequent damage to the equipment.
(7) EQUIPMENT DAMAGE. The ESC must only be lifted using the four lifting eyes.
(8) EQUIPMENT DAMAGE. The secondary support fixture must ONLY be used as a means
of levelling the ESM position. It is not designed to take the full weight of the ESM. The M8
lifting eyebolt must ALWAYS be used for lifting the ESM.
(9) EQUIPMENT DAMAGE. External means of supporting the weight of the ESM power
cables must be provided.
(10) EQUIPMENT DAMAGE. The serial data link facility must only be used by Ultra
approved personnel who have full knowledge of the system and its operational limits. This
facility is NOT available to normal users of the ESS.
(11) EQUIPMENT DAMAGE. Correct fuses must be fitted. Fitment of incorrect fuses may
result in damage to the ESC.
(12) EQUIPMENT DAMAGE: When connecting the ESM power cable to the motor terminals,
ensure that new Tab washers are always used.

Page x UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
CONDITIONS OF USE
CONDITIONS OF USE
(1) OIL COOLING: Oil cooling to the motor must be established for 15 minutes prior to
use.
(2) OIL COOLING: Oil cooling to the motor must be maintained for 30 minutes after use.
(3) OIL COOLING: Oil cooling to the motor must be maintained under all operational
conditions (i.e. when the motor is spinning in an energised or a de-energised state).
(4) OIL COOLING: Oil cooling to the motor must be maintained under non operational
conditions where the motor is subject to elevated temperatures in excess of 70ºC.
(5) OIL COOLING: Oil cooling to the motor must be maintained for a minimum period of
five minutes immediately prior to jogging the motor.
(6) ESC POWER CABLE: The ESC power cable must be LAPP cable type OLFLEX®
SERVO 9YSLCY-JB 0037026 or equivalent.
(7) ESC POWER CABLE: The ESC power cable must have a maximum length of 100 m
between the ESC and Junction Box.

Rev: B, 20 Apr 2010 UNCLASSIFIED Page xi
UNCLASSIFIED
MARKINGS
ELECTRIC START MOTOR
1 The Electric Start Motor (ESM) type E00000063 has been issued with a Manufacturers Self
Declaration of Conformity. This is issued against the following directive;
(1) ATEX Directive 94/9/EC.
2 The Declaration of Conformity currently covers use of the ESM in a Star configuration only.
3 The ESM is marked as follows:
CERTIFICATION NOT YET

COMPLETED

II 3 G Ex nA II T3 COMPLETED
4 Compliance with the essential health and safety requirements has been assured by compliance with
EN 60034-1:2004, EN 60079-0:2006 and EN 60079-15:2005.
ELECTRIC START CONTROLLER
5 The Electric Start Controller (ESC) type E00000064 has been issued with a Manufacturers Self
Declaration of Conformity. This is issued against the following directives;
(1) EMC Directive 2004/108/EC
(2) Low Voltage Directive 73/23/EEC
(3) Machinery Directive 2006/42/CE
6 The ESC is marked as follows:

COMPLETED
7 Compliance with the essential health and safety requirements has been assured by compliance with
EN 60204-1:2006.
8 Compliance with EMC requirements has been assured by compliance with EN 61800-3:2004.

Page xii UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
JUNCTION BOX
9 The Electric Start System Junction Box type E00000067 has been issued with a Third Party Type
Certificate No. KEMA99ATEX3172X. This is issued against the following directive;
(1) ATEX Directive 94/9/EC.
10 The Junction Box is marked as follows:
II 2 G EEx e II T5
II 2 D T100ºC
CABLE ASSEMBLY 2
11 Cable Assembly type E00000066 has been issued with a Manufacturers Self Declaration of
Conformity. This is issued against the manufacturer’s drawing 700017016_02.
12 The following standards are applicable to / referenced on cable drawing 700017016_02
(1) UL758 – Appliance Wiring Material incorporating:
a. Style 2750 – Shielded and Jacketed Cable
b. Style 1330 – Insulated Wire
(2) Low Voltage Directive 73/23/EEC – Cable is according to CE
(3) Habia Cable internal inspection plan HIP-G-630 – CSA and UL approved cables
13 The Cable is marked in accordance with the requirements of the UL style as follows; HABIA CABLE
AB UL AWM STYLE 2750 200°C 600 V

Rev: B, 20 Apr 2010 UNCLASSIFIED Page xiii
UNCLASSIFIED
CHAPTER 1
PURPOSE AND PLANNING INFORMATION

Rev: B, 20 Apr 2010 UNCLASSIFIED Page 1
UNCLASSIFIED
CHAPTER 1
PURPOSE AND PLANNING INFORMATION
CONTENTS
Page
Purpose 3
Brief Description 3
Mechanical Characteristics 4
Electrical Characteristics 4
Electrical Power Supplies 4
Mains Supplies 4
ACH supplies 5
Ratings 6
Operational Characteristics 8
Annual Running Requirements 9
Annual Running Requirements – Industrial Trent 60 9
Annual Running Requirements – Industrial RB211-24G(T) 10
Annual Running Requirements – Industrial RB211-H63 10
Speed 10
Operating Speeds – Industrial Trent 60 10
Operating Speeds – Industrial RB211-24G(T) 11
Operating Speeds – Industrial RB211-H63 11
ESM Overspeed Limit 11
Environmental Limitations 11
ESM Corrosion Resistance 12
TABLES
Page
Table 1 Equipment Weights And Dimensions 4
Table 2 Cable Weights and Dimensions 4
Table 3 ESM Rating 6
Table 4 S9 Ratings in Star Configuration 6
Table 5 S9 Rating in Delta Configuration 7
Table 6 T60 Annual Running Requirements 9
Table 7 T60 Electric Start System Fatigue Design Cycles 9
Table 8 T60 Operating Speeds 10
Table 9 ESM and ESM Power Cable Environmental Limitations 11
Table 10 ESC Environmental Limitations 12
Table 11 Junction Box Environmental Limitations 12
FIGURES
Page
Fig 1 ESC and ESM 3
Fig 2 ESM Duty Cycle in Star Configuration 7
Fig 3 ESM Duty Cycle in Delta Configuration 8

Page 2 UNCLASSIFIED Rev: B, 20 Apr 2010
UNCLASSIFIED
SUMMARY OF DATA
PURPOSE
1 The Electric Start System (ESS) is used to start a gas turbine (GT), in this application either the
Industrial Trent 60, RB211-24G(T) or RB211-H63 gas turbines.
BRIEF DESCRIPTION
2 The ESS comprises the following main items of equipment:
(4) Electric Start Motor (ESM) Type E00000063
(5) Electric Start Controller Unit (ESC) Type E00000064
(6) Junction Box Type E00000067
(7) ESC Power Cable Assembly (connecting ESC to Junction Box) – not Ultra supply
(8) ESM Power Cable Assembly Type E00000066 (connecting Junction Box to ESM)
Fig 1 ESC and ESM

UNCLASSIFIED
3 The ESM is an oil-cooled squirrel caged induction motor and is coupled to the gas turbine within the
engine enclosure. The ESC is an air-cooled variable speed drive and is located remotely from the engine
enclosure.
4 The ESC interfaces to the ESM using a set of interface cable assemblies via a junction box mounted
on the outside of the engine enclosure.
MECHANICAL CHARACTERISTICS
5 The weights and dimensions of the ESS equipment are detailed in Table 1 and Table 2.
TABLE 1 EQUIPMENT WEIGHTS AND DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT

ITEM
(mm) (mm) (mm) (kg)
Electric Start Controller Type E00000064 2036 1500 715 1300
Electric Start Motor Type E00000063 442 290 704 111
Junction Box Type E00000067 508 762 200 36
TABLE 2 CABLE WEIGHTS AND DIMENSIONS
DIAMETER LENGTH WEIGHT

ITEM
(mm) (m) (kg/m)
ESC Power Cable Assembly 42.6 ≤100 5.1

Type OLFLEX® SERVO 9YSLCY-JB 0037026
Mftr: LAPP (not Ultra supply)
ESM Power Cable Assembly Type E00000066 35.2 10 3.3
CONDITION OF USE
(1) ESC POWER CABLE: The ESC power cable must be LAPP cable type OLFLEX®
SERVO 9YSLCY-JB 0037026 or equivalent.
(2) ESC POWER CABLE: The ESC power cable must have a maximum length of 100 m
between the ESC and Junction Box.
ELECTRICAL CHARACTERISTICS
Electrical Power Supplies
6 The units within the ESS require the following power supplies.
Mains Supplies
7 The following mains supplies are required:
(9) ESC: 380-690 V ac three-phase 50/60 Hz rated at 300 kVA.

UNCLASSIFIED
WARNING
ELECTRICAL ISOLATION. THE ELECTRIC START SYSTEM EQUIPMENT DOES NOT

NOTE
The ESS has the facility to accommodate supplies in the range indicated above by adjustment of
tap settings on the Auto-Transformer contained within the ESC. The tap settings are 380V, 415V,
440V, 480V, 600V, 690V.
8 The system is specified with a mains supply tolerance of +/-5% of the mains supply voltage selected
at the tap setting on the Auto-Transformer contained within the ESC.
9 The total harmonic distortion (THD) produced by the ESC on the supply current is less than 10% at
rated load.
ACH supplies
10 The following ACH supplies are required:
(10) ESC : 110/230 V 60 Hz single-phase rated at 1 kVA.
WARNING


UNCLASSIFIED
PERFORMANCE AND LIMITATIONS
RATINGS
11 The ESM rating in star and delta configurations is summarised in Table 3.
TABLE 3 ESM RATING
Star Delta
IP rating IP56 IP56
Insulation Class H H
Maximum speed de-energized [rpm] 11 000 13 000
Duty cycle S1:
Rated output [kW] 175 155
Rated voltage [V rms] 390 390
Rated line current [A rms] 360 256
Rated frequency [Hz] 104 255
Power factor 0,86 0,86
Rated speed [rpm] 3 000 7 700
Duty cycle S9:
Power range [kW] 175 ≤ P ≤ 200 155 ≤ P ≤ 215
Voltage range [V rms] 390 ≤ Un ≤ 500 390 ≤ Un ≤ 500
Rated line current [A rms] 360 256
Frequency range [Hz] 104 ≤ f ≤ 205 255 ≤ f ≤ 434
Reference power factor 0,86 0,86
Maximum speed energized [rpm] 3 000 ≤ n ≤ 6 000 7 700 ≤ n ≤ 13 000
12 The duty cycle S9 (according to EN 60034-1:2004) is shown in Fig 2 for the ESM in star
configuration. The corresponding continuous and intermittent power ratings are summarised in Table 4.
TABLE 4 S9 RATING IN STAR CONFIGURATION
CONTINUOUS INTERMITTENT TORQUE ASSIST

RATING RATED POWER RATED POWER
(5000 TO 6000RPM)
(3000 TO 5000RPM)
S9 Duty Cycle Star 175kW 200kW 200kW

UNCLASSIFIED
6000rpm
Speed
Cycle repeated
four times
3000rpm
Time
Power
Continuous rated
power Intermittent rated Torque assist
power
Pref
Time
Torque Continuous rated

torque
Time
A E
B
C
F
D
Fig 2 ESM Duty Cycle in Star Configuration
NOTE
A= 3000rpm @ continuous rated torque for 30 minutes
B= 3000 to 5000rpm in 40 seconds @ intermittent rated power
C= 5000 to 6000rpm in 20 seconds @ torque assist
D= Run down to 0 rpm in de-energised state in 3 minutes
E= De-energised for 30 minutes with oil system on
F= Ramp period from standstill to 3000rpm
13 The duty cycle S9 (according to EN 60034-1:2004) is shown in Fig 3 for the ESM in delta
configuration. The corresponding continuous and intermittent power ratings are summarised in Table 5.
TABLE 5 S9 RATING IN DELTA CONFIGURATION
CONTINUOUS INTERMITTENT
RATING RATED POWER RATED POWER
(7700 TO 13000RPM)
S9 Duty Cycle Delta 155kW 215kW

UNCLASSIFIED
13000rpm
Speed
Cycle repeated
four times
7700rpm
Time
Power
Continuous rated
power Intermittent rated
power
Pref
Time
Torque Continuous rated

torque
Time
A D
B
C
E
Fig 3 ESM Duty Cycle in Delta Configuration
NOTE
A= 7700rpm @ continuous rated torque for 30 minutes

B= 7700 to 13000rpm in 60 seconds @ intermittent rated power
C= Run down to 0 rpm in de-energised state in 3 minutes
D= De-energised for 30 minutes with oil system on
E= Ramp period from standstill to 7700rpm
OPERATIONAL CHARACTERISTICS
14 The ESS provides sufficient energy to drive the HP shaft speed to ignition speed. After achieving
engine ignition the ESS provides energy to assist in the acceleration of the HP shaft.
15 For the industrial Trent 60 and RB211-H63, the ESM is permanently engaged to the HP spool of the
engine and will constantly be driven by the engine when the engine is running.

UNCLASSIFIED
16 For the industrial RB211-24G(T), the ESM is connected to the HP spool via an over-running clutch;
consequently the ESM is only coupled to the HP spool during a start and as such will not be driven by the
engine during normal engine operation.
17 Speeds and loads for the ESS are shown in Table 6 to Table 8.
Annual Running Requirements
18 The ESS is designed to operate the mission profiles specified in Table 6 for the industrial Trent 60
and the industrial RB211 families of gas turbine engine.
Annual Running Requirements – Industrial Trent 60
19 The ESS is designed to operate under the following mission profiles listed in Table 6.
TABLE 6 T60 ANNUAL RUNNING REQUIREMENTS
Annual Running Requirements for T60 Gearbox Baseload Mid-Merit Peak-

Under Differential Operational Profiles Mission Mission Lopping
Mission
Number of Normal starts per year 80 400 800
Mission duration (hours) 100 12 2
Total “on-load” running per year (hours) 8000 4800 1600
1
Purge cycle 80 x 30 min 400 x 15 min 800 x 5 min
Failed starts 20 x 30 min 100 x 15 min 200 x 5 min
Cool down cranks 160 x 5 min 800 x 5 min 1600 x 5 min
2
Crank-soak water wash 48 x 5 min 30 x 5 min 24 x 5 min
Number of Maintenance cranks/starts 30 x 30 min 20 x 15 min 20 x 5 min
Total crank time per year 4940 min 11950 min 13420 min
NOTES
(1) Purge cycle is required during the start sequence to purge the air inlet, the engine and
exhaust stacks of possible flammable products prior to ignition. Purge Cycle is required during
Normal Starts, Failed Starts, and Maintenance Starts.
(2) The Baseload and Mid-Merit wash requirement is based on three 5-minute cranks every 500
running hours. The Peak-Lopping wash requirement (based on maximum performance) is based
on three 5-minute cranks every 200 running hours.
20 Speeds and loads for the T60 ESS are shown in Table 6 to Table 8.
TABLE 7 T60 ELECTRIC START SYSTEM FATIGUE DESIGN CYCLES

1
T60 Operational Profiles Crank Cycles Crank Time On-Load Cycles On-Load Time
MTBO (Mean Time 15000 cycles 5000 hours 7500 cycles 50000 hours
Between Overhaul)
MTBF (Mean Time 48000 cycles 16000 hours 24000 cycles 160000 hours
between Failure)

UNCLASSIFIED
NOTE
On-load implies gas turbine is generating power.
Annual Running Requirements – Industrial RB211-24G(T)
21 The annual running requirements for the RB211-24G(T) are similar to those of the Industrial Trent 60.
Annual Running Requirements – Industrial RB211-H63
22 The annual running requirements for the RB211-H63 are similar to those of the Industrial Trent 60.
Speed
Operating Speeds – Industrial Trent 60
23 The ESS is designed to operate within speed ranges listed in Table 8:
(1) ISA day = 15°C
(2) Cold day = -40°C
(3) Hot day = 50°C
TABLE 8 T60 OPERATING SPEEDS

1
Condition Starter Shaft Speed (rpm)
60 Hz 50 Hz
Base Load ISA day 9964 9971
Cold day 9190 9233
Hot day 10112 10118
70% Load ISA day 9604 9604
Cold day 8805 8855
Hot day 9808 9760
Peak Load ISA day 10084 10073
Cold day 9190 9233
Hot day 10229 10214
Synchronous Idle ISA day 8265 8062
Cold day 7648 7471
Hot day 8687 8473
2
Sub-Sync. Idle ISA day 7225
Cold day 7225
Hot day 7225
NOTES
(1) Starter shaft speed = Industrial HP Trent HP shaft speed x 0.9995 (Starter Slower)
(2) For 60 Hz engine only.

UNCLASSIFIED
Operating Speeds – Industrial RB211-24G(T)
24 The engine cranking and purging speeds of the RB211-24G(T) are similar to those of the Industrial
Trent 60. The ESM however, runs at a ratio of 100:39 (ESM shaft speed:HP compressor speed).
Operating Speeds – Industrial RB211-H63
25 The engine cranking and purging speeds of the RB211-H63 are similar to those of the Industrial Trent
60.
ESM Overspeed Limit
26 The ESM is designed to withstand continuous rotation at 14200 rpm. The ESM is designed so the
critical speed of all rotating parts is above this limit. When subjected to an overspeed condition of 18500
rpm for 1 s the ESM remains safe.
ENVIRONMENTAL LIMITATIONS
27 The environmental limitations of the ESM and the ESM power cable are detailed in Table 9. Note that
the ESM rear termination cowl and ESM power cable have a lower temperature rating than the ESM.
TABLE 9 ESM AND ESM POWER CABLE ENVIRONMENTAL LIMITATIONS
Ambient Condition Range

Ambient Temperature -40°C to +100°C operational
-40°C to +200°C non-operational (ESM)
-40°C to +175°C non-operational (ESM rear
termination cowl and ESM power cable)
Relative Humidity Up to 100%
Altitude Range -500 m to +3500 m
28 The environmental limitations of the ESC are detailed in Table 10.

UNCLASSIFIED
TABLE 10 ESC ENVIRONMENTAL LIMITATIONS

Ambient Temperature -10°C to +40°C
Relative Humidity 0 to 80%
29 The environmental limitations of the Junction Box are detailed in Table 11.
TABLE 11 JUNCTION BOX ENVIRONMENTAL LIMITATIONS

Relative Humidity 0 to 95% non-condensing
ESM CORROSION RESISTANCE
30 Materials and coatings used in the design of the ESM meet the requirements of MIL-STD-810F,
Method 509.4.
STORAGE CONDITIONS
31 The storage limitations of the ESM and ESM power cable are detailed in Table 12.
TABLE 12 ESM AND ESM POWER CABLE STORAGE LIMITATIONS

Humidity Up to 100%
Time Period Up to 5 consecutive calendar years, subject
to in-storage maintenance
32 The storage limitations of the ESC are detailed in Table 13.
TABLE 13 ESC STORAGE LIMITATIONS

Relative Humidity 0 to 80%
Time Period Up to 5 consecutive calendar years, subject
to in-storage maintenance
33 The storage limitations of the Junction Box are detailed in Table 14.

UNCLASSIFIED
TABLE 14 JUNCTION BOX STORAGE LIMITATIONS

Relative Humidity Up to 100%
Time Period Up to 5 consecutive calendar years

UNCLASSIFIED
This page intentionally left blank

UNCLASSIFIED
CHAPTER 2
OPERATING INFORMATION
CONTENTS
Page
Introduction 2
Controls and indicators 2
ACH SUPPLY 3
System switch on 3
System switch off 3
TABLES
Page
Table 15 ESC Controls And Indicators 3
FIGURES
Page
Fig 1 ESC controls and indicators 2
Doc No. 1003795 Commercial In Confidence Chap 2

UNCLASSIFIED
INTRODUCTION
1 The Electric Start System is remotely controlled.
2 A jog switch (commissioning function only) and power supply indications are housed on the Electric
Start Controller. There are no controls or indicators on the Electric Start Motor or the Junction Box.
CONTROLS AND INDICATORS
WARNING
3 The jog switch (commissioning function only) and power supply indications are housed on the front of
the ESC cubicle at the top as shown in Fig 1. Table 15 provides a description of the controls and
indicators.
Jog switch and power

supply Indicators
Fig 1 ESC controls and indicators
Chap 2 Commercial In Confidence Doc No. 1003795

UNCLASSIFIED
TABLE 15 ESC CONTROLS AND INDICATORS
LEGEND DEVICE FUNCTION

ACH ON Red LED The ACH ON LED is illuminated when the ACH heaters are ON.
VOLTS ON Red LED The VOLTS LED is illuminated when the 380-690 V ac three-phase
50/60 Hz input supply is present.
JOG Key Switch The Jog function can be used during commissioning of the Electric Start
CONTROL System to “jog” the motor and ensure that the direction of rotation is
correct.
ACH SUPPLY
WARNING
CONDENSATION. THE ACH SUPPLY SHOULD BE APPLIED TO THE ESC AT ALL TIMES
4 To switch on the ACH heaters within the ESC, proceed as follows:
(1) Switch on the 110V/230V 60Hz single phase supply to the ESC at the external isolator.
(2) Ensure the ‘ACH ON’ LED on the top right of the ESC is illuminated.
SYSTEM SWITCH ON
CONDITION OF USE
OIL COOLING: Oil cooling to the motor must be established for 15 minutes prior to use.
5 To switch on the ESS proceed as follows:
(1) Ensure the oil supply is available and operational before starting Gas Turbine.
(2) Ensure the oil supply to the ESM is turned on for a minimum of 15 minutes.
(3) Switch on the 380-690 V 50/60 Hz three-phase mains supply to the ESC at the external
isolator.
(4) Ensure the ‘VOLTS ON’ LED on the top right of the ESC is illuminated.
(5) The ESS is now ready to be controlled via the external data link (see Note).
NOTE
The sequence of operations to start the Gas Turbine, run it to speed, the selection of power or
torque control, is determined by the customer and is outside the scope of this handbook.
SYSTEM SWITCH OFF
6 To switch off the ESS proceed as follows:
(1) Isolate the 380-690 V 50/60 Hz three-phase mains supply to the ESC at the external
isolator.

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(2) Ensure the ‘VOLTS ON’ LED on the top right of the ESC is extinguished.
(3) Ensure the ACH LED on the top right of the ESC is illuminated.
(4) After 15 minutes turn off the oil supply to the ESM.
CONDITION OF USE
OIL COOLING: Oil cooling to the motor must be maintained for 30 minutes after use.

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CHAPTER 3
TECHNICAL DESCRIPTION
CONTENTS
Page
Introduction 2
ESM 2
NOTE 3
ESC 3
ACH Supply 4
Status Indicators 5
Circuit Diagrams 5
Vacon Drive 6
Serial Data Link 6
Control Boards 6
Interface Boards 6
Trip Conditions 11
Interfaces – Inputs 12
Interfaces – Outputs 12
Junction Box 13
Cable Assemblies 13
System Interconnections 13
FIGURES
Page
Fig 1 ACH Supply 110V 4
Fig 2 ACH Supply 230V 4
Fig 3 Close Pre-Charge and Pre-Load Contactors 7
Fig 4 ESC Temperature Status 7
Fig 5 Close Main Contactors 8
Fig 6 Ready/Tripped 8
Fig 7 Normal/Alarm 8
Fig 8 Motor Thermistor 9
Fig 9 Speed Input and Power Input 9
Fig 10 Enable/Disable, Start/Stop and Speed Mode/Power Mode 9
Fig 11 Speed Indication and Power Indication 10
Fig 12 DeviceNet 10
Fig 13 Jog function 11
Fig 14 Hardwired/DeviceNet Control 11
Fig 15 (sheet 1 of 4) ESC circuit diagram 15
Fig 16 (sheet 1 of 3) ESM installation drawing 19
Fig 17 (sheet 1 of 3) ESC installation drawing 22

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INTRODUCTION
(6) Electric Start Motor Installation Kit Type E00002703
engine enclosure.
4 The ESC is an air-cooled variable speed drive and is located remotely from the engine enclosure.
ESM
6 The ESM is a high power density, oil cooled, four pole asynchronous induction machine.
7 The ESM is cooled by pumping oil through the ESM via an inlet port on the top of the ESM and an
exhaust port at the base of the ESM.
8 A single lifting eyebolt is fitted to the top of the ESM that is used for lifting purposes.
9 An auxiliary support pad is located on the top of the ESM body for customer use; refer to Fig 16 for
details. This pad allows a secondary support fixture to be attached.
10 Electrical power connections to the ESM are made via six M12 studs at the rear of the ESM.
Electrical earth/ground connections are made via three screws located on the back plate of the starter
and marked G1, G2, G3 refer to Fig 16 for details.
11 In addition to power connections to the ESM there is a signal connector on the top of the ESM body
near the starter mounting flange refer to Fig 16 for details. This connector provides an interface point to
the ESM over temperature protection devices (thermistors).
12 Blanking plugs are fitted to the motor oil ports for shipment purposes only. These plugs protect
foreign bodies contaminating the motor assembly while it is being transported or sitting in storage. A
magnetic drain plug is fitted to the stator sleeve oil sump to collect debris within the oil system.
13 A vent port is provided at the top of the ESM case. This should remain capped unless otherwise
specified.
NOTE
There may be some residual oil within the starter motor when received.

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14 An installation kit is supplied with the ESM. The installation kit allows the customer to electrically
configure the motor in a Star or Delta arrangement dependant upon the motor’s application. The star
shaped link allows the motor terminal studs to be connected in Star configuration. The rectangular delta
links allows the motor terminal studs to be connected in a Delta configuration. The contents of the
installation kits are defined in the table shown on Fig 16.
NOTE
Industrial Trent 60 and RB211-H63: Star connected
RB211-24G(T): Delta connected
15 Tab washers are fitted as part of the link securing arrangement to prevent the links, nuts and crimps
rotating and working free under vibration.
16 Custom M12 nuts are used to secure the terminal links and cable crimps to the motor terminal studs.
Custom nuts prevent maintenance engineers fitting any type of M12 nut that could damage the terminal
studs.
17 Separate to the ESM, a rear termination cowl is supplied. The fitting of this cowl is mandatory as the
ESM is powered by hazardous voltages. The IP56 rating of the motor is only achieved when the rear
termination cowl is fitted.
ESC
18 The ESC provides a variable-voltage, variable-frequency supply to the ESM.
19 The ESC is a box structure and has two lockable front doors.
20 Four lifting eyebolts are fitted to the top of the ESC that can be used for lifting purposes.
21 Cooling is provided by vent fans; air is drawn in through filtered louvres on the front at the bottom and
centre of the ESC and vented out through louvres on the front at the top of the ESC.
22 Electrical connection to busbars and terminal blocks are via cable glands mounted on gland plates on
the top or the bottom of the ESC. The input cabling is on the right hand side and the output cabling on the
left hand side.
23 The three-wire input supply connects to busbars which feed a high current three-phase EMC Filter
(X1). The EMC Filter output feeds the primary terminals of a hexaphase autotransformer (T1). T1 is fitted
with primary taps that enable operation from a three-phase input supply of 380V, 415V, 440V, 480V,
600V or 690V, setting of the primary taps is made during installation. T1 provides two three-phase
secondary output groups. The secondary windings are both 540 V and phase displaced by 30°. Each
secondary three-phase group feeds a six-pulse diode rectifier (D1 and D2).
24 The rectifier outputs are parallel connected via inter-phase transformers (IPT1 and IPT2) to form a
twelve-pulse rectifier. The positive dc outputs from each rectifier are fed to one inter-phase transformer
and the negative dc outputs to the other. The inter-phase transformer outputs form the dc link voltage
applied to the Vacon variable speed ac drive.
25 The variable voltage, variable frequency three-phase output from the Vacon ac drive is fed to a dV/dt
inductor (L3) which acts to slew the edges of the PWM output waveform thus reducing stress on the
insulation of the remotely connected induction motor. Busbars fitted after the dV/dt inductor provide the
connection point for the output motor cables.

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26 A pre-charge circuit is used to slowly charge the large input capacitance of the Vacon drive at power-
up. The pre-charge circuit is required to avoid heavy current-in-rush and resonant over-voltage at the dc
link when power is first applied to the ESC. Two three-phase contactors (CTR1 and CTR2) initially isolate
the inputs of the six-pulse rectifiers. An additional small pre-charge contactor (CTR3) and six-pulse
rectifier (D3) charges the drive input capacitance via power resistor (R1). When dc volts are established
at the drive input, the pre-charge contactor is opened and the two main input contactors are closed
enabling power to be transmitted through the ESC.
27 A pre-load circuit is required to magnetize the inter-phase transformers. A contactor (CTR4) across
the output of the pre-charge rectifier switches in the pre-load power resistor (R1) when the drive is not
delivering any output power. Power resistor R1 performs a dual function – pre-charge and pre-load.
Contactor CTR4 can only close if the pre-charge contactor (CTR3) is open.
ACH Supply
28 The ACH supply can be either 110 V or 230 V.
28.1 The 110V ACH supply (Fig 1) is applied via TB4 (110V) and TB2 (N). A link is fitted between
TB7 and TB8 to complete the ACH circuit via transformer T3.
Opens
@40°C
TB3 FS19 TB8 TB7 CTR1 TH1
230V
230V
TB4 FS20 T3
ACH ACH
110V ACH H1 H2
Supply Thermostat LED1
TB2 ON 120W 120W
N
Fig 1 ACH Supply 110V
28.2 The 230V ACH supply (Fig 2) is applied via TB3 (230V) and TB2 (N). A link is fitted between
TB6 and TB7 to complete the ACH circuit.
Opens
@40°C
TB3 FS19 TB6 TB7 CTR1 TH1
230V
TB4 FS20
ACH ACH
110V ACH H1 H2
Supply Thermostat LED1
TB2 ON 120W 120W
N
Fig 2 ACH Supply 230V
29 The 110 V/230 V 60 Hz single-phase ac supply to the ESC anti-condensation heaters (H1 and H2) is
applied via fuse FS19 (230 V) or FS20 (110V), normally closed contact CTR1 and the ACH Thermostat
contact TH1. CTR1 operates such that when CTR1 is de-energised the contact closes and the ACH
supply is applied to heaters H1 and H2. The ACH Supply is also applied to the ACH ON LED (LED1)
causing it to illuminate. The ACH Thermostat contact under normal conditions is closed but if the
temperature in the unit exceeds 40°C the contact opens and the ACH supply is removed from H1, H2 and
LED1 causing it to extinguish.

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Status Indicators
30 The status indicators are housed on the top right of the ESC cubicle. Each indicator comprises a
single LED and operates as describe in Paras 32 to 33.
31 The ESS cubicle houses the following LEDs:
(1) ACH ON
(2) VOLTS
32 ACH on. The ACH ON LED (LED1) (Fig 1 and Fig 2) is powered by the 110 V / 230 V 60 Hz ACH
supply. LED1 is illuminated when the 110 V / 230 V 60 Hz single-phase ACH supply is present, contactor
CTR1 is de-energised and the ACH thermostat contact is closed.
33 Volts. The VOLTS LED (LED2) is powered by the 115 V 60 Hz supply from the secondary of
transformer T2. LED 2 is illuminated when the 380-690 V ac three-phase 50/60 Hz input supply is
present.
Circuit Diagrams
34 Fig 15 provides the circuit diagram for the ESC.

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Vacon Drive
35 The Vacon Drive controls the ESM in response to speed or power demand inputs. The drive also
performs secondary processing sequencing and status monitoring functions.
36 The Power Unit contains an inverter bridge which consists of IGBT switches that produce a
symmetrical, 3-phase PWM-modulated AC voltage.
37 The Motor Application Control is based on microprocessor software. The microprocessor controls the
motor based on the information it receives through measurements, parameter settings, control I/O and
control keypad. The motor application control signal calculates the IGBT on and off settings. Gate drivers
convert these signals into a suitable format to drive the IGBT inverter bridge.
Serial Data Link
38 The ESC may be operated via a serial data link from a PC or laptop. The serial data link cable is
connected via the maintenance connector on the front panel (refer to Fig 17 (Chap 3)).
39 The laptop can be used to read system parameters, status data, warnings and alarm settings.
CAUTION
EQUIPMENT DAMAGE. The serial data link facility must only be used by Ultra approved
personnel who have full knowledge of the system and its operational limits. This facility is
NOT available to normal users of the ESS.
Control Boards
40 The control unit of the inverter comprises the control board and a number of option boards connected
to the five slots (A to E) on the control board. The control board is connected to the power unit through
fibre optic cables.
Interface Boards
41 The Vacon Drive is fitted with five interface boards:
(1) Option Board A3 – Basic I/O Board. Relay board with two relay outputs and one thermistor
input fitted to Slot B.
(2) Option Board A8 – Basic I/O Board. Standard I/O board with galvanically isolated digital
inputs/outputs and analogue inputs/outputs fitted to Slot A.
(3) Option Board B4 – I/O Expander Board. Vacon NX I/O expander board with one galvanically
isolated analogue input and two galvanically isolated analogue outputs (standard signals
0(4)…20 mA) fitted to Slot C.
(4) Option Board B5 – I/O Expander Board with three relay outputs fitted to Slot D.
(5) Option Board C7 - Fieldbus Board. Instead of sending and receiving information to and from
frequency converters through I/O, you can connect them to a fieldbus. Vacon NX frequency
converters can be connected to the DeviceNet using a fieldbus board (Option Board C7
fitted to Slot E). The converter can then be controlled, monitored and programmed from the
Host system.

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42 The drive incorporates a soft start facility which limits the input current drawn on start up. This
operates via the following three steps:
(1) Close Pre-Charge and Pre-Load Contactors (Fig 3). Relay output RO3 on Option Board B5
is used to control the Pre-Charge contactor CTR3. CTR3 can only be closed when the Pre-
Charge Lockout relay RO3 is de-energised. With RO3 open RL1 is de-energised, RL1 NC
contact is closed and 230V is applied to CTR3 via RO1.
The Pre-Load contactor CTR4 can only be closed when the Pre-Charge routine is complete.
It is then opened/closed depending upon whether the drive is delivering output power to the
motor (open if output power is greater than 10kW).
RL1
OPT-B5
RO3
230V RL1
0V
CTR3
RL1 0V
OPT-B5
RO1
CTR4
PSU1 PSU1
CTR3 0V
+24V
Fig 3 Close Pre-Charge and Pre-Load Contactors
(2) ESC Temperature Status (Fig 4). A ESC Temperature Status signal is applied to digital
input DIN6 on Option Board A8. Thermistor Relays TR1-3 contacts are closed when they
are energised and the wound component temperatures are OK. Thermostat switch TH2 is
located in the top of the ESC enclosure and opens under an overtemperature condition.
+24V (from Option Board A8) is applied to DIN6 to signal an OK condition. If a thermistor
(embedded in each limb of the wound components) registers overtemperature or open
circuit then the associated thermistor relay contacts will open. DIN6 will register a fault
condition and disable the drive output. External Fault (fault code F51) will be recorded in the
fault history and indicated at the ESC console.
TH2
opens at 80degC
OPT-A8
TR3 DIN6 High = Wound component temperatures OK

Thermistor Relay 3
Low = Overtemperature
TR2
Thermistor Relay 2
TR1
Thermistor Relay 1
+24V
Fig 4 ESC Temperature Status

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(3) Close Main Contactors (Fig 5). A contactor enable signal is provide from digital output DO1
on Option Board A8. When DO1 is high RL2 remains de-energised and the 230V 60Hz
supply from the secondary of T2 is applied to energise CTR1 and CTR2 via the RL2 NC
contact. When DO1 is low RL2 is energised, RL2 NC contact opens and CTR1 and CTR2
are de-energised.
RL2
230V
CTR1 CTR2
0V
OPT-A8
RL2
24V
Contactor
DO1
Enable
Fig 5 Close Main Contactors
43 Control Interface:
(1) Ready/Tripped (Fig 6). Relay output RO2 on Option Board B5 provides indication of the
ready/tripped state. When the RO2 contact is open a tripped condition is indicated, when the
RO2 contact is closed a Ready condition is indicated. Refer to Para 44 for trip conditions.
OPT-B5 Open = Tripped

Closed = Ready
RO2
Ready/
Tripped
Fig 6 Ready/Tripped
(2) Normal/Alarm (Fig 7). Relay output RO2 on Option Board A3 provides indication of the
alarm state. When the RO2 contact is open an alarm condition is indicated, when the RO2
contact is closed a normal condition is indicated.
OPT-A3 Open = Alarm

Closed = Normal
RO2
Normal/
Alarm
Fig 7 Normal/Alarm
(3) Motor Thermistor (Fig 8). The Drive Module continuously monitors the motor temperature
via the thermistor input TI1 on Option Board A3 and indicates an alarm if the resistance of
the connected motor thermistor exceeds a predetermined value, indicating an overheated
motor.

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OPT-A3
TI1 +VE
Motor
Thermistor
TI1 -VE
Fig 8 Motor Thermistor
(4) Speed Input 4-20 mA (Fig 9). A speed demand reference analogue input is applied to AI1
on option Board A8. The Drive Module uses the speed demand reference when Speed
Control mode is active. The analogue input is within the current range 4-20 mA. The speed
input is only active when the Drive Module is in Hardwired control mode.
OPT-A8
+10V REF
AI1 +VE
Speed Input
4 - 20mA
AI1 -VE
AI2 +VE
Power Input
4 - 20mA
AI2 -VE
+24V OUT
GND
Fig 9 Speed Input and Power Input
(5) Power Input 4-20mA (Fig 9). A power demand reference analogue input is applied to AI2 on
option Board A8. The Drive Module uses the power demand reference when Power Control
mode is active. The analogue input is within the current range 4-20mA. The power input is
only active when the Drive Module is in Hardwired control mode.
(6) Enable/Disable (Fig 10). An enable/disable control signal is applied to digital input DIN1 on
Option Board A8. When the enable/disable control signal is high, enable is signalled. When
the enable/disable control signal is low, disable is signalled.
OPT-A8
Enable/Disable DIN1 High = Enable
Low = Disable
Start/Stop DIN2 High = Start
Low = Stop
Speed Mode/ DIN3 High = Power Mode
Power Mode Low = Speed Mode
Fig 10 Enable/Disable, Start/Stop and Speed Mode/Power Mode
(7) Start/Stop (Fig 10). A start/stop signal is applied to the digital input DIN2 on Option Board
A8. When the start/stop signal is high, start is signalled. When the start/stop signal is low,
stop is signalled. The start/stop signal input is only active when the Drive Module is in
Hardwired control mode.
(8) Speed Mode/Power mode (Fig 10). A mode signal is applied to digital input DIN3 on Option
Board A8. When the mode signal is high, power mode is selected. When the mode signal is
low, speed mode is selected. The mode signal input is only active when the Drive Module is
in Hardwired control mode.

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(9) Speed indication 4-20 mA (Fig 11). An analogue speed indication is provided from analogue
output AO1 on Option Board B4. The analogue signal is a current signal in the range 4-
20mA.
OPT-B4
AI1 +VE
AI1 -VE
AO1 +VE
Speed Indication
4 - 20mA
AO1 -VE
AO2 +VE
Power Indication
4 - 20mA
AO2 -VE
GND
GND
GND
+24V
Fig 11 Speed Indication and Power Indication
(10) Power Indication (Fig 11). An analogue power indication is provided from analogue output
AO2 on Option Board B4. The analogue signal is a current signal in the range 4-20mA.
(11) DeviceNet (Fig 12). A bi-directional DeviceNet is interfaced to Option Board C7. The
DeviceNet interface provides the main control interface of the ESS.
OPT-C7
V -VE
CAN_L
Drain DeviceNet
CAN_H
V +VE
Fig 12 DeviceNet

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(12) Jog Key Switch (Fig 13). A jog/not jog signal is applied to digital input DIN6 Option Board A8
via a Jog key switch. With the Jog key switch set to the Jog position the jog signal is set to
high (+24V (from Option A8) connected to DIN5) and a Jog signal is applied. With the Jog
key switch set to the Not Jog position the jog signal is set to low (+24V (from Option Board
A8) disconnected from DIN5) and a Not Jog signal is applied. The jog function is used
during commissioning to ensure correct rotation (clockwise when looking at the shaft from
the output end) before fitting the starter to the engine. The Jog function is only active when
both the NCDrive RS232 Maintenance interface is in use and the Jog key switch is set to
the Jog position. When activated the jog function causes the ESM shaft to rotate at 30rpm
(in the normal direction of operation for 4s. Activation of the Jog function is restricted to
minimum intervals of 20s.
OPT-A8
Jog/Not Jog
DIN5 High = Jog
Low = Not Jog
+24V
Fig 13 Jog function
(13) Hardwired/DeviceNet control (Fig 14). A Hardwired/DeviceNet control is applied to digital

input DIN4 on Option Board A8. Under normal operating conditions there is no wire link
between the +24 V output from Option Board A8 to DIN4, the input to DIN4 is set to low
signalling DeviceNet control. When a wire link is connected between the +24 V output from
Option Board A8 to DIN4, the input to D4 is set to high signalling hardwire control.
OPT-A8
Hardwired/DeviceNet Control
DIN4 High = Hardwired Control
Low = DeviceNet Control
+24V
Fig 14 Hardwired/DeviceNet Control
Trip Conditions
44 Any of the following states initiates a drive trip:
(1) Drive Over Temperature
(2) Motor Over Temperature
(3) Drive Over Voltage
(4) Drive Over Current
(5) Internal Drive Fault
(6) Ground Fault
(7) Autotransformer Overtemperature
(8) IPT Overtemperature
(9) Line Inductor Overtemperature
(10) DV/DT Inductor Overtemperature

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(11) Communications Failure
(12) Output Phase Supervision
(13) Inverter Overtemperature
(14) Analogue Input <4mA
(15) Slot Fault (defective option board or slot)
(16) Inverter Fan Cooling
45 The trip state is reset by one of the following actions:
(1) Toggling of Enable/Disable input
(2) System Power Down
Interfaces – Inputs
46 The ESS accepts the following signals from the customer’s Engine Control System.
(1) Enable signal
(2) Start signal
(3) Power Mode select
(4) Speed input
(5) Power input
Interfaces – Outputs
47 The ESS outputs the following signals to the customer’s Engine Control System.
(1) Ready/Tripped status
(2) Normal/Alarm status
(3) Running/Stopped status
(4) Power signal
(5) Speed signal

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Junction Box
48 The Junction Box is used to make a transition between the interconnecting cables used in the normal
environment to those used in the higher temperature environment within the engine enclosure. The
junction box is mounted on the outside of the enclosure in a potentially hazardous location (zone 2).
49 The Junction Box has a removable front panel. Cable entry is via cable glands mounted on gland
plates on each side of the Junction Box. The Junction Box is mounted to the engine enclosure using four
mounting lugs, two at the top and two at the bottom.
50 Termination of the cable power cores, earth cores and screens are made to terminal blocks inside the
Junction Box. The cable earth cores and screens are isolated from the Junction Box structure and are not
connected to Junction Box earth.
Cable Assemblies
51 There are two types of cable assemblies:
(1) Cable Assembly 1; connects from the ESC to the Junction Box.
(2) Cable Assembly 2; connects from the Junction Box to the ESM.
52 Cable 1 Assembly is not part of the Ultra Electronics supply.
53 Cable Assembly 2 is a high temperature cable that is used within the Gas Turbine enclosure to
connect to the ESM. Cable Assembly 2 is in the supply of Ultra Electronics.
54 Connection details are given in the Cable Data Sheets in Chapter 4.
System Interconnections
55 For the electric start system interconnections, refer to the Cable Data Sheets in Chapter 4 and the
System Interconnection Diagram for the specific gas turbine application.
56 The power connection details between the ESC and ESM are given for the industrial Trent, RB211-
H63 and RB211-24G(T) gas turbines in Table 16,Table 17, and Table 18 respectively (see Note).
TABLE 16 INDUSTRIAL TRENT POWER CONNECTIONS
Connection Industrial Trent

ESC L1 L2 L3
ESM U1 V1 W1
TABLE 17 INDUSTRIAL RB211-H63 POWER CONNECTIONS
Connection Industrial RB211-H63

ESC L3 L2 L1
ESM U1 V1 W1

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TABLE 18 INDUSTRIAL RB211-24G(T) POWER CONNECTIONS
Connection Industrial RB211-24G(T)

ESC L1 L2 L3
ESM U1, W2 V1, U2 W1, V2
NOTE
(1) The ESM is connected in star configuration for the industrial Trent and RB211-H63 gas
turbines.
(2) The ESM is connected in delta configuration for the industrial RB211-24G(T) gas turbine.
(3) Rolls Royce Canada advises that the ESM is required to rotate in opposite directions for the
industrial Trent and RB211-H63 gas turbines. This phase rotation may be accommodated in the
power connections detailed in Table 16 and Table 17 .
(4) For the electric start system connections for the industrial Trent gas turbine, refer to System
Interconnection Diagram M60007834.

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409 410 FS18

GLAND PLATE GLAND PLATE 4A
TOP LEFT TOP RIGHT 1 115V 059 062
RR
0V 063
LOCAL PE LOCAL PE SHEET 2
411 412 115V
GLAND PLATE GLAND PLATE 060
BOTTOM LEFT BOTTOM RIGHT SS
2 0V
061 6 PULSE
LOCAL PE LOCAL PE 408 PE DIODE
T2 RECTIFIER 3
BUSBAR
415 416 32
DOOR LEFT DOOR RIGHT R1
1 L1 2 T1 6 +VE 046 048
058 040 043 L1 1/3 A1 120R
LOCAL PE LOCAL PE 35
417 414 3 L2 4 T2 5 D3
FAN CTR4
PE BUSBAR 044 L2
HOUSING 041
056 A2
5 L3 6 T3 7/9 047
PE BUSBAR 4 -VE
PE REAR 057 042 045 L3
418 WALL 230
R1 231
CTR3 229
LOCAL PE 049 052

232
037 038 039
233 FS7 FS8 FS9 6 PULSE
4A 4A 4A DIODE 055
OUTPUT 540V RECTIFIER 1 054
FS1 dV/dT
T1 200A INDUCTOR
L1-1 007 013 1 L1 2 T1 025
HEXAPHASE AUTO TRANSFORMER L1 +VE
L1-A L1-B 019 L1 L3 OUTPUT
FS2 FS12
200A 031 250A
L2-1 008 014 3 L2 4 T2 IPT1 034
L2 +VE U
L2-A L2-B 020 X4
FS3 FS13
D1 L1
200A 250A
L3-1 009 015 5 L3 6 T3 026 L2 032
L3 -VE V
L3-A L3-B 021
L1
CTR1 033
LINE W
EMC
INDUCTOR 1 FS14
FILTER 035 250A
404 X3
X1 402
INPUT LOCAL FS15 L2
PE PE 250A
001 1 004 L1 0V
L1 L1 L1 38 5V BUSBAR
41 0V 403
38 PE
002 1 005 L2 41 0V 44 0V 6 PULSE
L2 L2 L2 48 0V BUSBAR
44 5V
60 0V DIODE 407
48 0V RECTIFIER 2
003 1 006 L3 60 0V 69 L2 FS16
L3 L3 L3 69 0V FS4 PE 250A
0V 200A 036
010 016 1 L1 2 T1 BUSBAR
400 L1
L1-2 L1-A L1-B 022 L1 FS17 L3
FS5 027 250A
200A +VE
011 017 3 L2 4 T2 030
L2 -VE
380V
415V
440V
480V
600V
690V
PE LOCAL L2-2 L2-A L2-B 023
FS6 IPT2 -VE
PE 200A D2
012 018 5 L3 6 T3 028 L2
PE STUD 401 L3 -VE
FRONT L3-2 L3-B 024
L3-A PE
BOTTOM OUTPUT 540V LINE 406
RIGHT INDUCTOR 2 CTR2 PE
PE PE BUSBAR
BUSBAR BUSBAR
PE
225
PE STUD 229
FRONT 405
TOP 228 228
RIGHT LOCAL
226 PE
227 227
Fig 15 (sheet 1 of 4) ESC circuit diagram

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120
TO TBY-2 4 -VOUT
NOTE TB9 CTR2 CTR1 PSU1 504
116 138 117 FG 3
X5 COMPRISES 4 IN SERIES 6 +VOUT
CONNECTED SUPPRESSORS 14 13 14 13
E OPT-B5 NO NO
X6 COMPRISES 2 IN SERIES 118 1 ACL PE BUSBAR
GN/YE 500 22 RO1 COM
CONNECTED SUPPRESSORS RD FROM RR 155
1 2 ACN +VOUT 7
157 (SHEET 1) 5 -VOUT
TB15
FS19 TB62 TB10 CTR4 (PRELOAD) 62 TO HH
TB3 2A 119 120 2
100 101 162 NOTE:CTR4 COIL 158
CONNECTIONS ARE TBY BK 234 TO THERMISTOR RL1
D4
230V FLYING LEADS 121 RELAYS (L) 140 TBY 132 139
23 RO1 NO SHEET 4
TO (L) 4 3 A2 A1
141
PSU1-4
CTR4
FS20 TB56 X5A-D TB21
TB4 122 F1 AUX
102 4A 103 163 25 RO2 COM
WH WH
110V
ALSO SEE 3 WAY TML PLC
142 BLOCK
READY/ WIRES 134 TB16 L
ANTI- X6A-B TRIPPED AND 135 PMES PART BU
TB22 25236A64146C
CONDENSATION 123 M1
TB58 26 RO2 NO L
HEATER TB2 BN
164 M
SUPPLY
(L) L
143 BK
104 F2
TB13 TO OPT-A8
N 160
PIN 7
BU 105 108 SHEET 3 N
501 133
28 RO3 COM
LAMP H1 144
120W BRAKE TB17 N
1 PE
BUSBAR SIGNAL 4UF
ACH TB50
166 R N 352 C1 350 1
TB1 ON 127
H2
TO
120W 131 (L) FF 353C2 351 2
29 RO3 NO 145 159 146 147
106
502 21 14 4UF TBX
148 RL2
115 TB51 TBX & TBY 2 WAY BU
PE 165 TO TB30 LAMP TML BLOCK
BUSBAR CTR1 CTR2 M2
SHEET 3 2 PMES PART
A1 A1 25242-672 BN M
TB18 VOLTS R
149 A2 A2 E BK
TB5 OPT-A3 150 151
TB11
124 FROM SS E GN/YE
21 RO1 NC (N) SHEET 1
CTR2 RL1 060
107 TO
125 126 NC 127 FF E GN/YE
PRECHARGE
(230V) 22 21 12 21 152
109
505
PE FAN
TB12
110 128 TH3 HOUSING
22 RO1 COM TB19
CTR3
129 A1 A2 130 OPEN
TO AT 70°C
TB6 153
101 EE
X2 F3 FROM BB
TB52 (N)
TB14 161 140
OPENS AT SPARE
230V INPUT 40°C
CTR1
LINK 6 & 7 TB7 BRAKE
22 21 F1 UNIT 156
TB23 154
111 112 134 TEMP TB53 TB20
NC TH1 25 RO2 COM TRIP
FROM
ACH ALSO SEE EE
THERMOSTAT WIRES 122 159 130
110V INPUT AND 123 FROM HH
LINK 7 & 8 TB8 113 230V 115V NORMAL/ (N)
26 RO2 NO 155
ALARM TB24
135 REMOVE LINK FOR
28 T11+VE RB211 BRAKING 237 TO THERMISTOR
114 0V 0V APPLICATION RELAYS (N)
T3 SHEET 4
29 T11-VE
PE
503 BUSBAR
TB44
136 WH
MOTOR
THERMISTOR TB45
137 RD
F4
ALSO SEE
WIRES 200-203
SHEET 3

UNCLASSIFIED
OPT-A8
OPT-A8
1 +10V REF
TB26 (CONT) TB32 OPT-A8
206
F4 ENABLE/ 8 DIN1 (CONT)
ALSO SEE DISABLE FROM PP
WIRES 136 & 137 216
SHEET 2 14 DIN4
TB36 (COMMS MODE)
200 WH
2 AI1 +VE TB27
SPARE
SW1
SPEED
JOG
INPUT
TB37 TB33 KEYSWITCH
4 -20mA 201 BK 3 AI1 -VE TB28 217 214
208
(GND ISOL) START/ 9 DIN2 2 1
STOP 218 NO FROM NN
15 DIN5
TB38
202 WH
4 AI2 +VE
POWER TB29 TB34

209 219
INPUT SPEED MODE/ 10 DIN3 16 DIN6
4 -20mA TB39
203 BN 5 AI2 -VE POWER MODE
F5 220
(GND ISOL) ALSO SEE TO TH2 SHEET 4
WIRE 204
THIS SHEET
TB25
204 11 CMA
6 24V OUT
TB30
210
+24V 12 24V OUT 17 CMB
F5
ALSO SEE 211
WIRES 206, 208 18 AO1 +VE
& 209 THIS SHEET +24V
TO TB51
RL2
SHEET 2 A1 19 AO1 -VE
TB35
222
A2 20 DO1
NC
160 221 21 22
FROM TB13 SHEET 2 7 GND 212 215
TB31 CTR3
TO LL
213
TO NN 215
+24V FROM LL
214
TO TR1
PIN 11
SHEET 4
LINK FOR TO PP
HARDWIRED
MODE

UNCLASSIFIED
OPT-B4
1 AI1 +VE
2 AI1 -VE
F6
TB40 237 235 236
300 WH FROM TB20 SHEET 2
3 AO1 +VE
234 238 239
FROM TB15 SHEET 2
SPEED
INDICATION 233 230 227
4 -20mA TB41
301 RD
4 AO1 -VE
TB42 A1 A2 A1 A2 A1 A2
302 WH
5 AO2 +VE
(SEE SHEET 1)
(SEE SHEET 1)
THERMISTORS
THERMISTORS
THERMISTORS
MOUNTED ON T1
MOUNTED ON L2
P1 P1 P1
(SEE SHEET 1)
MOUNTED ON IPT1
POWER 232 TR1 229 TR2 226 TR3
INDICATION
4 -20mA TB43
303 OR
6 AO2 -VE P2 P2 P2
11 14 11 14 11 14
(SEE SHEET 1)
(SEE SHEET 1)
THERMISTORS
THERMISTORS
THERMISTORS
MOUNTED ON L1
MOUNTED ON L3
(SEE SHEET 1)
7 GND
MOUNTED ON IPT2
231 228 225
8 GND
213 224 223
FROM TB31 SHEET 3
9 GND CABINET O/T

THERMOSTAT
220 205
10 +24V FROM TB34 SHEET 3
OPENS AT
TB46 OPT-C7
304 WH TH2 70°C
1 V -VE
TB47
305 WH
2 CAN_L
3 DRAIN
DEVICENET
TB48
306 BN
4 CAN_H
TB49 TERMINAL RAIL PHYSICAL ARRANGEMENT

307 BK
5 V +VE
TB1 TB18
TB54
TB19 TB35
MOTOR
THERMISTOR
SPARE TB55 TB36 TB62

UNCLASSIFIED
15° Mounting Flange designed to: 760.7
° SAE Standard 413
AS968 Rev C
Issued 1986-02 249
Reaffirmed 2004-03
Spline designed to: 220 Est C of G

° SAE Standard
AS972 Rev B
Issued 1977-07
Reaffirmed 2004-03
The tapped hole
in the end of the
Motor Shaft must
not be used to lift
or manoeuvre
the Motor
171.5
Ø 233
Ø 277
289.6
125
218
Interface 'O'Rings 60
Specification:
Flange - Part No. 100553 M10 Earth Scavenge/Drain Port
11
Shaft - Part No. 100552 both sides 1 1/2 SAE Port J1926-1
85 (ISO 11926-1)
Jacking Feet, fitted with 90 200 (Blanking Plug removed)
189 1.5D 3/8-24-UNJF-3B Oil Vent Port NOTES:-
Stainless Steel Keenserts to ° EPCO Inc. Magnetic Zero Leak 3/4 SAE to J1926-1
MS51381 (KH624-J)(2 each side) Gold Inspection Plug. (ISO 11926-1) 1) Installation Instructions
Location Pin to accept screw length Part No. 22 H-S12M - Hex Type. Blanking Plug: 25188a64176c
0.51"Min to 0.6" Max when ° Plug 1.13" across flats The Motor connections can be configured in star or delta
1 Off Location Pin Ø0.375" on a Jacking Feet are not being used Viton 'GF' 'O' Ring Seal. dependent on Target Engine.
10" PCD and protruding a max the 3/8" holes must be fitted Part No.100592
0.375" from surface of the with sealing bolts and seals as Use this drawing in conjunction with the handbook 1003795
Signal
Flange, positioned as shown. detailed on sheet 2 and 3 to install the motor.
Connector
Prior to installation ensure the following are available:-
Lifting Eye 2D M8X1.25 screw
lock stainless steel wire coil
inserts to BS 7751-1 when lifting ITEM PART NUMBER
NUMBER DESCRIPTION
eye is not being used the M8
hole must be fitted with sealing 1 E00000063 Motor Assembly 1
bolt and seal as detailed on
60 2 E00002703 Motor Cowl Assembly 1
sheet 2 and 3
35 3 E00000066 High Temperature Cable Assembly 1
45
70
Aux-Pad
4 off 1.5D1/4-28 UNJF-3B
Stainless Steel Keenserts to
MS51831 (KNH428J) to accept
screw length 0.315" Min
to 0.395"Max when the aux pad Aux-Pad
Oil Inlet Port is not being used the 1/4" holes Detail
3/4 SAE to J1926-1 must be fitted with sealing bolts Scale 1:1
(ISO 11926-1) and seals as detailed on
(Blanking Plug removed) Sheet 2 and 3
General View - Rear
Fig 16 (sheet 1 of 3) ESM installation drawing

UNCLASSIFIED
Lifting Eyebolt
Signal M8 Collar Z&P
Oil Vent Port Connector
3/4 SAE to J1926-1 M8 Sealing
(ISO 11926-1) Bolt Signal Connector TYP M83723/83K 10-06N
Vent Plug: 25188a64176c M8 Sealing
Washer 6 Way Connector for Thermistor Sensors
1/4" Sealing
Bolt PIN No.
1/4" Sealing 1 T1_a
Washer 2 T1_b
Motor Assembly 3
E00000063 4
Oil Inlet Port 5 T2_a
3/4 SAE to J1926-1 6 T2_b
(ISO 11926-1)
(Blanking Plug fitted)
Themistors
Barring feature
Terminal Hex Drive PTC Type A, (IEC 34-11 Part 2)
Assy Aid 36mm across flats <750 Ohms at room
temperature::> 4000 Ohms above 180°C
Star Link
Tab Washer
M12 Nut
Custom Made
Motor Assembly
Part View Motor Cowl Assembly
M10 Stainless Steel Nut Cable Cowl E00002703
of Terminals showing Installation Jig used to
fix the terminals at the correct height and Spring Washer Assembly
angle. Refer to the Handbook (1003795) for full 10mm ss
installation instructions Angle Position
Washer - Ground
M6 Washer
Plain Washer 10mm ss
M6 Copper Crimp Lug 90 Deg
M6
Tag Ring Term M10 Washer
M6x 20
Plain Washer 10mm ss Cap Head Screw
TAG Ring TML M6 25mm2 90° Angle Position
Screw M6X25 Screw M10x40
Hex HD SS Terminate Hex HD ss A4-80 Washer - Terminal Cable Entry
Cable Screens
to G1 and G2 Scavenge/Drain Port M12 Copper
Terminals Crimp Lug 90 Deg
1 1/2 SAE to J1926-1
(ISO 11926-1)
(Blanking Plug fitted)
NOTES
Screw M6X30 Hex HD SS :
1. Cable Entry
Refer to the Handbook for
configuration set up and full
Plain Installation Instructions
Washer
10mm ss 2. Electrical Connections
Spring Crimp cable cores and secure
Washer with the installation kit fixings
10mm ss
Refer to the Handbook 1003795
M10 for configuration set up and
Crimp Earth Cores Stainless full installation instructions
and secure to Steel Nut
G1, G2 & G3 3. Designed in accordance with
3/8" 3/8" Rolls Royce Electric Start
Sealing Sealing Both Cable Screens Exploded View - Rear
Tag Ring System Requirement GTES 10579
Bolt Washer to be insulated
Star Configuration Term M10
using Heat Shrink
Item 2.20 Earth
Magnetic Cable
Plug
Motor Assy - Star Configuration
Motor Cable Cowl Removed

UNCLASSIFIED
M8 1/4" M12 Nut Delta
Sealing Sealing Custom Made Link
Bolt M8 Washer 1/4" M12
Lifting Eyebolt Sealing Sealing Tab Copper Crimp Cable Cowl M6 M6x 20 Cap
M8 Collar Z&P Oil Inlet Port
Motor Assembly Signal Washer Bolt Washer Lug 90 Deg Assembly Washer Head Screw
3/4 SAE to J1926-1
Connector
(ISO 11926-1)
Oil Vent Port (Blanking Plug fitted)
3/4 SAE to J1926-1
(ISO 11926-1)
Blanking Plug: 25188a64176c Barring Feature
Hex Drive
36mm across flats
Terminal Assy Aid

Cable Entry
Refer to the Handbook
for configuration set up
and full installation
instructions
Part view of Terminals showing
Installation Jig used to fix the
terminals at the correct height
and angle. Refer to the Handbook
1003795 for full installation
instructions
TAG Ring TML

M6 25mm2 90°
Screw M6 X 25
Hex HD ss A4-80 Terminate M10 Stainless
Cable Screens Steel Nut
to G1 and G2 Spring Washer
Terminals M6 M6 Copper Crimp 10mm ss
Washer Lug 90 Deg
Plain Washer
Angle Position 10mm ss
M10 Stainless Washer - Ground
Steel Nut
Spring Washer
Plain Earth Screw M10x40 Tag Ring
10mm ss Scavange/Drain Port
Washer Cable Hex HD ss A4-80 Term M10
10mm ss Tag Ring 1 1/2 SAE to J1926-1
Term M10 Plain (ISO 11926-1)
Screw M6X30 Washer (Blanking Plug fitted) Earth
Hex HD SS
Motor Assembly 10mm ss Cable
E00000063
Crimp Earth Cores

and secure to Exploded View - Rear
G1, G2 & G3
Delta Configuration
Both Cable Screens
to be insulated Motor Cowl Assembly
using heat shrink E00002703
Item 2.19 Signal Connector TYP M83723/83K 10-06N NOTES:
6 Way Connector for Thermistor Sensors 1. Cable Entry
PINNo. Refer to the Handbook 1003795

3/8" 3/8"
Sealing Sealing
for configuration set up and
1 T1_a full installation instructions
Washer Bolt 2 T1_b
Magnetic Plug 3 2. Electrical Connections
4
5 T2_a Refer to the Handbook for
Motor Assy - Delta Configuration 6 T2_b configuration set up and full
installation instructions
Motor Cable Cowl Removed 3. Designed in accordance with
Thermistors Rolls Royce Electric Start
System Requirement GTES 10579
PTC Type A, (IEC 34-11 Part 2)
<750 Ohms at room
temperature::> 4000 Ohms above 180°C

UNCLASSIFIED
Input Gland Plate Top

Output Gland Plate Top
Top View 60° Unit lifted from top

using 4 Eyebolts
Louvered Vent
Outlet with Filter
Medium, secured M12 Earth Stud
with self retaining
screws
Key Switch
& LED'S
General View
Scale 1:10
3 Hinges
Louvered Vent
Estimated Inlet with Filter ITEM NO PART NUMBER DESCRIPTION QTY
Centre of Gravity Medium, secured
with self retaining 1 E00000064 Electric Start Controller 1
(Est CoG)
screws
NOTES:-
1. Installation Instructions
Use this drawing in conjunction with Handbook 1003795
Front View to install the Controller
Left View M12 Earth Stud Right View "C" Section provides
attachment to floor Prior to install ensure the following are available
Output Gland Bottom

Input Gland Bottom
4 Clearance Holes
for base fixings Ø15
Bottom View Mounting Detail
Fig 17 (sheet 1 of 3) ESC installation drawing

UNCLASSIFIED
Do not block the area

in front of Air Vent
370 370
680
AA
Space claim with doors fully open 120 degrees

and for air ventilation (over full height of enclosure)
Do not block the area

in front of Air Vent
Top & bottom lock

uses Allen to lock
Metric Size 8
Middle lock is locked
with key
MIDDLELOCK
Detail X Detail AA
Scale 1 : 2 Scale 1 : 1

UNCLASSIFIED
NOTE:
1. Input and Output Cables terminated with M10 Cable Lugs. Cables Lugs are
bolted to the Input Busbars.
Refer to Handbook instructions
Input Terminals
AC Drive Module
NOTE: Installers responsibility to drill plates
Input Terminals
Detail V
Scale 1 : 3
AC Control Unit
Fixes onto M6 Studs
Earth Stud
Output Fuses
Cross Sectional View &

Controller - Front
Gland Plate Detail
Gland Plate X 4 on input

and output
Fixed to floor via 4 holes

Exploded View Of Bottom Fixings

UNCLASSIFIED

UNCLASSIFIED
CHAPTER 4
INSTALLATION SPECIFICATION
CONTENTS
Page
INTRODUCTION 3
Electric Start Motor 3
NOTE 4
Electric Start Controller Unit 4
Junction Box 4
Cable Assemblies 5
INSTALLATION PHILOSOPHY 6
Summary Of Work And Responsibilities 6
LIFTING ARRANGEMENTS 7
WEIGHTS 7
SPACE REQUIREMENTS 7
SAFETY 8
EFFECTS OF ENVIRONMENT 8
EFFECT ON ENVIRONMENT 9
Electrical Power Supplies 9
Mains Supplies 9
ACH supplies 9
KEEP-ALIVE REQUIREMENTS 9
COOLING 10
ASSEMBLY PROCEDURES 11
Electric Start Motor 11
ESM with Star Configuration (Industrial Trent 60 and RB211-H63 Applications) 12
ESM with Delta Configuration (RB211-24G(T) Application) 24
Electric Start Controller 33
Junction Box 45
TABLES
Page
Table 1 Core lengths for star connection 16
Table 1 Mains Supply Fusing 34
Table 2 ACH Supply Fusing 35
Table 3 ESC Internal Fuses 36
Table 4 Junction box terminal blocks 48
Table 5 Cable Data Sheets 52
FIGURES
Page
Fig 1 ESM Star Link 12
Fig 2 ESM Star Link Fitted 13
Fig 3 ESM oil system ports 15
Fig 4 ESM cable core lengths, and cable locations in cowl 16
Fig 5 ESM Star Configuration Core Termination 18
Fig 6 ESM connections – star configuration 19
Fig 7 ESM terminal clearance and crimp arrangement – star configuration 20

UNCLASSIFIED
FIGURES
Page
Fig 8 ESM Ground terminal assembly 21
Fig 9 ESM SIGNAL connector 22
Fig 10 ESM Cowl Refitting 23
Fig 11 ESM Delta Links 25
Fig 12 ESM Delta Links Fitted 26
Fig 13 ESM oil system ports 27
Fig 14 ESM connections – delta configuration 29
Fig 15 ESM terminal clearance and ESM crimp arrangement – delta configuration 30
Fig 17 ESM Cowl Refitting 32
Fig 18 ESC 33
Fig 19 ESC Doors 37
Fig 20 Hexaphase autotransformer 38
Fig 21 ESC mains supply input busbars 39
Fig 22 Cable crimp input busbar 40
Fig 23 ESC ACH connections 40
Fig 24 Terminal block connection procedure 41
Fig 25 Terminal block connection (1) 41
Fig 28 ESC control and monitor interface connections 43
Fig 29 ESC three-phase output cable connections 44
Fig 30 Cable crimp output busbar 44
Fig 31 Junction Box 45
Fig 32 Group cabling diagram 51

UNCLASSIFIED
INTRODUCTION
(2) Electric Start Motor Installation Kit Type E00002703
engine enclosure.
4 The ESC is an air-cooled variable speed drive and is located remotely from the engine enclosure.
Electric Start Motor
6 The ESM is a high power density, oil cooled, four pole asynchronous induction machine.
7 The ESM is cooled by pumping oil through the ESM via an inlet port on the top of the ESM and an
exhaust port at the base of the ESM.
8 A single lifting eyebolt is fitted to the top of the ESM that is used for lifting purposes.
9 An auxiliary support pad is located on the top of the ESM body for customer use; refer to Fig 16 for
details. This pad allows a secondary support fixture to be attached.
10 Electrical power connections to the ESM are made via six M12 studs at the rear of the ESM.
Electrical earth/ground connections are made via three screws located on the back plate of the starter
and marked G1, G2, G3 refer to Fig 16 (Chap 3) for details.
11 In addition to power connections to the ESM there is a signal connector on the top of the ESM body
near the starter mounting flange refer to Fig 16 (Chap 3) for details. This connector provides an interface
point to the ESM over temperature protection devices (thermistors).
12 Blanking plugs are fitted to the motor oil ports for shipment purposes only. These plugs protect
foreign bodies contaminating the motor assembly while it is being transported or sitting in storage. A
magnetic drain plug is fitted to the stator sleeve oil sump to collect debris within the oil system.
13 A vent port is provided at the top of the ESM case. This should remain capped unless otherwise
specified.

UNCLASSIFIED
NOTE
There may be some residual oil within the starter motor when received.
14 An installation kit is supplied with the ESM. The installation kit allows the customer to electrically
configure the motor in a Star or Delta arrangement dependant upon the motor’s application. The star
shaped link allows the motor terminal studs to be connected in Star configuration. The rectangular delta
links allows the motor terminal studs to be connected in a Delta configuration. The contents of the
installation kits are defined in the table shown on Fig 16 (Chap 3).
NOTE
Industrial Trent 60 and RB211-H63: Star connected
RB211-24G(T): Delta connected
15 Tab washers are fitted as part of the link securing arrangement to prevent the links, nuts and crimps
rotating and working free under the vibrations generated by the motor or external environment conditions.
16 Custom M12 nuts are used to secure the terminal links and cable crimps to the motor terminal studs.
Custom nuts prevent maintenance engineers fitting any type of M12 nut that could damage the terminal
studs.
17 Separate to the ESM, a rear termination cowl is supplied. The fitting of this cowl is mandatory as the
ESM is powered by hazardous voltages. The IP56 rating of the motor is only achieved when the rear
termination cowl is fitted.
WARNING
ENCLOSURE RATING. THE MOTOR IP56 ENCLOSURE RATING IS ONLY ACHIEVED WITH
THE REAR TERMINATION COWL FITTED.
Electric Start Controller Unit
18 The ESC provides a variable-voltage, variable-frequency supply to the ESM.
19 The ESC is a box structure and has two lockable front doors.
20 Four lifting eyebolts are fitted to the top of the ESC that can be used for lifting purposes.
21 Cooling is provided by vent fans; air is drawn in through filtered louvres on the front at the bottom of
the ESC and vented out through louvres on the front at the top of the ESC.
22 Electrical connection to busbars and terminal blocks are via cable glands mounted on gland plates on
the top or the bottom of the ESC. The input cabling is on the right hand side and the output cabling on the
left hand side.
23 The ESC gland plates are supplied undrilled. The installer is responsible for drilling the gland plates
and for the provision and fitting of cable glands.
Junction Box
24 The Junction Box is used to make a transition between the interconnecting cables used in the normal
environment to those used in the higher temperature environment within the engine enclosure. The
junction box is mounted on the outside of the enclosure in a potentially hazardous location (zone 2).

UNCLASSIFIED
25 The Junction Box has a removable front panel. Cable entry is via cable glands mounted on gland
plates on each side of the Junction Box. The Junction Box is mounted to the engine enclosure using four
mounting lugs, two at the top and two at the bottom.
26 Termination of the cable power cores, earth cores and screens are made to terminal blocks inside the
Junction Box. The cable earth cores and screens are isolated from the Junction Box structure and are not
connected to Junction Box earth.
Cable Assemblies
27 There are two types of cable assemblies:
(7) Cable Assembly 1; connects from the ESC to the Junction Box.
(8) Cable Assembly 2; connects from the Junction Box to the ESM.
28 Cable 1 Assembly is not part of the Ultra Electronics supply.
29 Cable Assembly 2 is a high temperature cable that is used within the Gas Turbine enclosure to
connect to the ESM. Cable Assembly 2 is in the supply of Ultra Electronics.
30 Connection details are given in the Cable Data Sheets in Chap 4.

UNCLASSIFIED
INSTALLATION PHILOSOPHY
Summary Of Work And Responsibilities
31 The system integrator is to provide materials and articles as indicated in this specification, other
relevant specifications and in Approved Drawings. A brief summary of the main items of work is as
follows:
(1) The provision of a power supply to the ESC including supply cables.
(2) The provision of a control and monitoring interface to the ESC including the supply of
cables.
(3) The provision of power interface cables for connection between the ESC and the Junction
Box.
(4) The provision of a signal interface between the ESM and the ESC including the supply of
cables.
(5) The provision of earth straps for connection to the ESC, ESM and the Junction Box.
(6) The provision and fitting of the inlet and outlet oil supply pipes to the ESM.
(7) The provision and fitting of breather piping to the ESM (if required).
(8) The drilling of gland plates on the ESC and the Junction Box.
(9) The provision of glands for the gland plates on the ESC and the Junction Box.
(10) The efficient protection of the equipment from damage.
(11) The provision of ESM site installation fasteners.
(12) The provision of an Emergency Stop Facility
32 The above outline is for general guidance and is not exhaustive. For further information, reference is
to be made to the individual paragraphs and figures of this and other relevant specifications.
33 The equipment installer is to provide materials and articles as indicated in this specification, other
relevant specifications and in Approved Drawings. A brief summary of the main items of work is as
follows:
(1) The fitting of the ESC to the installation site, including the provision of fasteners.
(2) The fitting of the ESM to the Gas Turbine, including the provision of fixings.
(3) The fitting of a star connection or delta connection to the ESM.
(4) The fitting of the rear cowl to the ESM.
(5) The fitting of the Junction Box to the installation site, including the provision of fasteners.
(6) The fitting of earth straps between the installation site earth fixing point and the ESC.
(7) The fitting of earth straps between the installation site earth fixing point and the ESM.

UNCLASSIFIED
(8) The fitting of earth straps between the installation site earth fixing point and the Junction
Box.
(9) The adjustment of auto transformer primary links at the ESC according to the installation
site power supply specification.
(10) The termination and connection of the ac supply cables to the ESC.
(11) The termination and connection of the control and monitoring interface cable to the ESC.
(12) The termination and connection of the power and thermistor cables between the ESC and
the Junction Box.
(13) The termination and connection of the power and thermistor cables between the ESM and
the Junction Box.
LIFTING ARRANGEMENTS
34 The ESC is designed for installation using a suitable lifting device attached to the four M12 eyebolts
fitted to the top of the ESC.
35 The ESM is designed for installation using a suitable lifting device attached to the M8 eyebolt fitted to
the top of the ESM. The ESM also has 4 handling feet fitted with 1/4-28-UNJF-3B Keensert Helicoils
which can be used in conjunction with the eyebolt to move the ESM.
WEIGHTS
36 The weight of the ESC is 1300 kg and the estimated centre of gravity is shown on the Top Level
assembly drawing E00000063.
37 The weight of the ESM is 111KG, excluding the rear cowling, terminal links and cable assemblies.
The weight and estimated centre of gravity of the motor is shown on drawing E00000064.
38 The weight of the ESM with the rear cowling, terminal links and cable assembly components is 115
kg and the estimated centre of gravity is shown on the installation drawing E00002093.
39 The weight of the Junction Box is 36 kg.
40 The weight of the ESM power cable assembly is 3.3kg/m
SPACE REQUIREMENTS
41 The space requirements for the installation of the ESS are broken into individual drawings for each
mechanical assembly.
42 Drawing E00002093 – ESM Installation Drawing
43 Drawing E00002754 – ESC Installation Drawing
44 Drawing E00000067 - Junction Box Assembly Drawing

UNCLASSIFIED
SAFETY
WARNINGS
(1) EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START MOTOR IS 111KG.
(2) EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START CONTROLLER IS

1300 KG.
(3) EXCESSIVE WEIGHT. THE WEIGHT OF THE JUNCTION BOX IS 36KG
(4) EXCESSIVE WEIGHT. THE WEIGHT OF THE ESM CABLE ASSEMBLY IS 3.3KG/M.
45 Care should be taken during the transportation and installation of the equipment to avoid damage to
the following:
(1) The end of the rotor shaft on the ESM.
(2) The cable terminals protruding from the rear of the ESM
(3) The cable assembly protective cowl.
(4) The signal connector fitted to the ESM.
(5) The two earth studs on the ESC.
(6) The controls and connectors mounted on the front of the ESC.
(7) The jog switch and RS232 interface connector protective cover on the front of the ESC.
(8) The two earth studs on the junction box.
46 Ensure that the ESC, ESM and Junction Box earths are bonded to the site earth system (<5mΩ)
before connecting to the mains supply.
WARNING
LETHAL VOLTAGE. THE EQUIPMENT EARTH STRAPS MUST BE SECURELY ATTACHED TO

ALL UNITS.
EFFECTS OF ENVIRONMENT
47 The ESC is vented by fans located at the top of the ESC. Air is drawn in, via filters, through the
louvres at the bottom front of the ESC and exhausted through the louvres at the top front of the ESC. As
the fans keep the ESC cool during operation, it is imperative that the air intake and exhaust are kept free
from obstruction.
48 The ESM is oil cooled and a vent is fitted to the top of the ESM. If the vent is used, then it is
imperative that it is kept free from obstruction.

UNCLASSIFIED
EFFECT ON ENVIRONMENT
49 The units within the ESS dissipate the following wild heat:
(1) ESC : The ESC wild heat is <15kW. This is emitted to the local environment.
(2) ESM : The ESM is cooled by oil. The heat rejection to the oil is <50kW.
ELECTRICAL POWER SUPPLIES
50 The units within the ESS require the following power supplies.
Mains Supplies
51 The following mains supplies are required:
(1) ESC : 380-690V ac three-phase 50/60Hz rated at 300kVA.
WARNING

NOTE
The ESS has the facility to accommodate supplies in the range indicated above by adjustment of
tap settings on the Auto-Transformer contained within the ESC.
ACH supplies
52 The following ACH supplies are required:
(1) ESC : 110/230V 60 Hz single-phase rated at 1kVA.
WARNING

KEEP-ALIVE REQUIREMENTS
53 No keep-alive policy is required. The ESC is fitted with anti-condensation heaters to protect the unit
from the ingress of moisture during periods of non-operation. After the installation of the equipment the
110/230V 60 Hz ACH supply must be maintained to prevent damage.

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COOLING
54 The ESC is vented by fans located at the top of the ESC. Air is drawn in through filtered louvres on
the front at the bottom and centre of the ESC and vented out through louvres on the front at the top of the
ESC. As the fans keep the ESC cool during operation, it is imperative that the air intakes and exhaust are
kept free from obstruction.
55 The ESM is oil cooled and requires a supply of oil for cooling. Connection to the oil supply is by inlet
and outlet ports mounted on the ESM. The oil supply specification is as follows:
(1) Synthetic oil compliant with MIL-PRF-23699.
(2) Oil temperature is 0°C to 70°C
(3) Oil pressure is not to exceed 14 bar
(4) Oil flow is not to exceed 30 litres per minute
56 For oil temperatures between 15°C and 70°C, a constant pressure oil supply is required.
(5) The nominal setting for the constant pressure system is 8.9bar. This provides a nominal 27
litres per minute of oil at an inlet temperature of 65°C.
57 For oil temperatures below 15°C, a constant flow oil supply is required.
(6) The nominal setting for the constant flow system is 15 litres per minute. This corresponds to
a nominal pressure of 8.9 bar at an oil inlet temperature of 15°C.
58 The ESM is oil cooled and a vent is fitted to the top of the ESM. If the vent is used, then it is
imperative that it is kept free from obstruction.
CONDITIONS OF USE
(1) OIL COOLING: Oil cooling to the motor must be established for 15 minutes prior to
use.
(2) OIL COOLING: Oil cooling to the motor must be maintained for 30 minutes after use.
(3) OIL COOLING: Oil cooling to the motor must be maintained under all operational
conditions (i.e. when the motor is spinning in an energised or a de-energised state).
(4) OIL COOLING: Oil cooling to the motor must be maintained under non operational
conditions where the motor is subject to elevated temperatures in excess of 70ºC.

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ASSEMBLY PROCEDURES
59 The following tools are required for installation of the ESS:
(1) Wrenches: 10mm; 13mm; 17mm; 19mm.
(2) Pliers.
(3) Crimp Tool (suitable for the M6 and M12 crimps from the cable assembly kit).
(4) Allen Key: size 6mm; size 8mm.
(5) Torque Wrench 10Nm (7.38lbf) - 50Nm (36.88lbf).
(6) Calliper Gauge.
(7) Terminal Screwdriver.
(8) Terminal Assembly Aid E00002759 (part of ESM installation kit)
(9) High current milli-ohmeter (injection current ≥110A, resolution better than 10µΩ)
Electric Start Motor
60 Ensure the following has been completed and available before commencing installation:
(1) The ESM installation kit is available, E00002073
(2) The oil supply piping is fitted at the installation site.
(3) The V band clamp or retaining bolts to secure the ESM to the Gas Turbine are available
(supplied by installation site)
(4) The ESM Power Cable Assembly Type E00000066
61 Before the ESM (Fig 16 (Chap 3)) is installed the ESM power connections must be configured. The
ESM connections can be configured as a star connection or as a delta connection.
(1) The star connection, as illustrated in Fig 16 (Chap 3) Sheet 2, is required for the industrial
Trent 60 and RB211-H63 Gas Turbines; to install the ESM with the ESM connections in a
star configuration refer to Para 62.
(2) The delta connection, as illustrated in Fig 16 (Chap 3) Sheet 3, is required for the RB211-
24G(T) Gas Turbine; to install the ESM with the ESM connections in a delta configuration
refer to Para 64.

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ESM with Star Configuration (Industrial Trent 60 and RB211-H63 Applications)
62 To install the ESM with the ESM connections in a star configuration proceed as follows:
CAUTION
EQUIPMENT DAMAGE: When connecting the ESM power cable to the motor terminals,
(1) To configure the ESM connections in a star configuration proceed as follows:
a. From the installation kit, obtain the Star Link to secure to the terminal studs as detailed
in the following steps.
b. From the installation kit, obtain the Terminal Assembly Aid E00002759. This will be
used to determine the height of the Star Link connections. Attach to rear of the motor
adjacent to terminal U2 (Fig 1).
c. From the installation kit, fit a single terminal nut to the terminal marked U2 (Fig 1)
running the nut down until it touches the Terminal Assembly Aid. Repeat the process
for terminals V2 and W2.
ESM
Terminal Pin U2
Tab Washer
Nut M12
Star Link
Terminal Pin V2
Terminal Pin W2
Fig 1 ESM Star Link

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d. Fit an unused tab washer (Fig 1) from the installation kit to the terminals marked U2, V2
and W2.
e. Fit the star link to the terminals marked U2, V2 and W2 (Fig 1).
f. Fit an unused tab washer from the installation kit over the terminals marked U2, V2 and
W2.
g. Fit the remaining terminal nuts to the terminals marked U2, V2 and W2.
CAUTION
EQUIPMENT DAMAGE. Do not over tighten assembly as damage to the motor may occur.
h. Using a 19mm spanner hold the motor side nut stationary and tighten the other nut to a
torque of 25Nm (18.4lbf).
i. Using pliers fold one of the tabs on each washer towards the star link.
j. Fold the remaining straight tab on each washer (Fig 2) against its adjacent nut to
prevent loosening of the connection under vibration.
ESM
Ensure two full

threads are visible
Nut M12
Folded Tab
Terminal Pin
Star Link
Fig 2 ESM Star Link Fitted

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WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START MOTOR IS 111KG.
(2) Using a suitable lifting device offer the ESM to the installation site.
CAUTION
EQUIPMENT DAMAGE. The secondary support fixture must ONLY be used as a means of
levelling the ESM position. It is not designed to take the full weight of the ESM. The M8
NOTE
An M8 eyebolt fitted to the top of the ESM is provided as a lifting aid. The ESM also has 4
handling feet fitted with 1/4-28-UNJF-3B Keensert helicoils which can be used in conjunction
with the eyebolt to move the ESM into position.
(3) Align the locating dowel fitted to the ESM pad face at 3 o’clock (when viewed from shaft
end) with the hole in the Gas Turbine pad face.
(4) Interface the end of the ESM rotor shaft with the Gas Turbine using the locating dowel as an
alignment aid.
(5) For the industrial Trent and RB211-H63 installations, secure the ESM to the Gas Turbine
using a V band clamp. For RB211-24G(T) installations, secure the ESM using a set of
retaining bolts.
(6) Remove the shipment blanking plugs from the oil inlet and oil outlet ports.
(7) Connect the incoming oil supply pipe to the oil inlet port on the top of the ESM as shown in
Fig 3.
(8) Connect the oil outlet pipe to the oil drain port at the base of the ESM as shown in Fig 3.
(9) Connect the oil breather pipe to the vent at the top of the ESM as shown in Fig 3.

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Fig 3 ESM oil system ports
WARNING

ALL UNITS.
(10) Connect a suitably sized Earth Strap between one of the earth connection points on the
ESM casing and the installation site earth fixing point. The location of the ESM earth
connection points is shown in Fig 16 (Chap 3).
(11) Before commencing any further work on the ESM installation, conduct an earth bonding test
between the ESM body and the installation site earth. Confirm that the measured resistance
is less than 5mΩ.
(12) Remove the cable gland nuts, washers and seals from the rear protective terminal cowl
refer to Fig 10.
(13) Pass the ends of the two cables from the ESM power cable assembly E00000066 through
the cable gland nuts, washers and seals and through the two gland bosses in the rear
terminal cowl. Ensure that the cowl earth stud is oriented at the bottom of the overall
assembly.
(14) Cut the two power cables to length.
(15) Remove 370mm of insulation from the outer sheath of each power cable to allow the inner
cores (i.e. power cores and earth cores) and screens to be made off. The outer insulation
should not be back further than the positions of the cable gland nuts when cowl is installed.
(16) On each power cable unravel cable screens and twist strands together to form a single core
for each power cable.
(17) Cut inner cores to length in accordance with Table 1 and Fig 4.

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TABLE 1 INNER CORE LENGTHS FOR STAR CONNECTION
Core Power Cable 1 Power Cable 2
Earth 370mm 370mm

Yellow/Green
(3 per)
Screens 360mm 360mm

(1 per)
Brown 260mm 260mm
Black 290mm 290mm
Grey 270mm 270mm
Crimp
Power
Cable
Inner core
Length
Cowl
Power Power
Cable 1 Earth Cable 2
Gland Entry Stud Gland Entry
Fig 4 ESM cable core lengths, and cable locations in cowl
(18) Remove sufficient insulation from the inner cores to enable the crimp connections to be
made without leaving conductors exposed after crimping.
(19) Using the M12 crimps from the cable assembly kit make off the crimp connections to the
three power cores for each of the two power cables.

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(20) Using the M6 crimps from the cable assembly kit make off the crimp connections for the
three earth cores for each of the two power cables and the screen for each of the two power
cables.
(21) Fit heatshrink sleeving over each power cable screen and shrink onto screen.
CAUTIONS
(22) The two power cables to the ESM have a minimum bend radius. For final assembly of the
ESM there must be sufficient length in both power cables to ensure the minimum bend
radius of the power cable is not compromised.
(23) The power cables must be externally supported as close to the ESM as possible. This is
necessary to prevent excessive loads being applied to the ESM cowl, terminal pins and
mounting flange.
CAUTIONS
ensure that new Tab washers and Terminal Assembly Aid are always used.
(24) Terminate the inner cores to the ESM terminals in accordance with, Fig 6, Fig 32, the Cable
Data Sheets provided in Table 5 and the following procedure:
a. From the installation kit, obtain the Terminal Assembly Aid E00002759. This will be
used to determine the height of the core terminations.
b. From the installation kit, fit a single terminal nut to the terminal marked U1 (Fig 5)
running the nut down until it touches the Terminal Assembly Aid. Repeat the process
for terminals V1 and W1.

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Nut Tab
Washer
Cable
Crimp
The Tab washers
are supplied flat and
are bent over the
nut, as show above
after the nuts have
been fully tightened
Angle
Tab Position The Angle
Washer Washer Position washer
ensures that the
crimps can not
rotate out of the
correct position
Nut fitted down on to location tool to ensure

correct height is maintained
The Terminal Assembly Aid is located

on the cowl bolt holes to ensure
accurate positioning of the terminal
crimps
Fig 5 ESM Star Configuration Core Termination
c. Fit an unused tab washer (Fig 5) from the installation kit to the terminals marked U1, V1
and W1.
d. Fit an angle position washer (Fig 5) from the installation kit to the terminals marked U1,
V1 and W1.

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e. Fit two M12 crimped power cores to the terminals marked U1, V1 and W1, Refer to
Fig 6, Fig 32 and the Cable Data Sheets provided in Table 5.
U1 V1 W1 U1 V1 W1
G1 G1 G1 G3 G2 G2 G2 G3
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
(Screen)
(Screen)
Brown
Brown
Black
Black
Grey
Grey
Power Power
cable 1 cable 2
Fig 6 ESM connections – star configuration
NOTE
There are three connections to G1, three connections to G2 and two connections to
G3.
CAUTION
EQUIPMENT DAMAGE. Ensure the M12 crimped power cores are fitted using the installation
aid. If fitted incorrectly shorting to the cowl may occur.
f. Using the Terminal Assembly Aid locate the Angle Position washer and power core
crimp bodies as indicated in Fig 7.
CAUTION
EQUIPMENT DAMAGE. Ensure there is a minimum clearance of 13mm between adjacent
terminals as shorting between terminals may occur.
g. Ensure there is minimum clearance of 13mm between adjacent terminals (Fig 7).

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Minimum
clearance
13mm
U1 Minimum
clearance
G1 13mm
W2 U2
G3
W1 V1
G2
V2
Fig 7 ESM terminal clearance and crimp arrangement – star configuration
h. Fit an unused tab washer from the installation kit over the terminals marked U1, V1 and
W1.
i. Fit the remaining terminal nuts to the terminals marked U1, V1 and W1, tightening
finger tight until no clearance remains in the bolted connections.
j. Using a 19 mm spanner hold the motor side nut stationary and tighten the other nut to a
torque of 25 Nm (18.4 lbf).
k. Using pliers fold one of the tabs on each washer towards the star link.
CAUTION
l. Fold the remaining straight tab on each washer against its adjacent nut to prevent
loosening of the connection under vibration.
m. For power cable 1 fit three M6 crimped earth cores to earth location G1 (refer to Fig 6,
Fig 32 and the Cable Data Sheets provided in Table 5) and secure using an M6 bolt,
angle position washer and plain washer. Ensure crimp positioning washer is located
correctly as shown in Fig 8.
n. For power cable 2 fit three M6 crimped earth cores to earth location G2 (refer to Fig 6,
Fig 32 and the Cable Data Sheets provided in Table 5) and secure using an M6 bolt,
angle position washer and plain washer. Ensure crimp positioning washer is located
correctly as shown in Fig 8.

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o. For power cables 1 and 2 fit two M6 crimped earth screen to earth location G3 (refer to
Fig 6, Fig 32 and the Cable Data Sheets provided in Table 5) and secure using an M6
bolt, angle position washer, plain washer and spring washer. Ensure crimp positioning
washer is located correctly as shown in Fig 8.
p. Ensure that each earth core crimp body is facing in the direction indicated in Fig 7.
CAUTION
EQUIPMENT DAMAGE. Ensure there is a minimum clearance of 13 mm between adjacent
q. Ensure there is minimum clearance of 13 mm between adjacent terminals as shown in

Fig 7.
r. Using a 10 mm spanner tighten the M6 bolt secure 3 earth core crimps from power
cable 1 to G1, 3 earth core crimps from power cable 2 to G2 and the 2 earth screens to
G3 to a torque of 15.0 Nm (11.1 lbf).
Bolt
For screen
connection only 2
Cable cable crimps are
Crimps required the top
cable crimp is left
off
Notch locates with feature on angle

position washer to ensure correct
orientation
Fig 8 ESM Ground terminal assembly

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(25) Connect the interface cable to the signal connector on the top of the ESM, refer to Fig 9,
Fig 32 and the Cable Data Sheets provided in Table 5.
SIGNAL Connector
Fig 9 ESM SIGNAL connector
(26) Before fitting the cowl, ensure that sufficient power cable length is retained to reach the
ESM and to maintain the correct cable bend radius.
CAUTIONS
(27) Use the six M6 socket head cap screws with washers from the installation kit to secure the
cowl to the ESM.
(28) Fit cable gland seal, washer and gland nut. Tighten gland nut to fully seal the power cables.
(29) Remove the earth cable (for cowl to ESM body) and M10 crimps from the installation kit.
(30) Remove sufficient insulation from each end of the earth cable to enable the M10 crimp
connections to be made without leaving conductors exposed after crimping.

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(31) Using the M10 crimps from the installation kit make off the crimp connections to each end of
the earth cable.
(32) Connect one end of the earth cable to the cowl earth stud using M10 nut, plain washer and
spring washer.
(33) Confirm that the measured resistance between the ESM body and the cowl is less than
5mΩ.
ESM
M6 Hex Head
Screws (6 off)
Cowl
Cable Glands
(2 off)
Earth Cable
Connections
Fig 10 ESM Cowl Refitting

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ESM with Delta Configuration (RB211-24G(T) Application)
63 To install the ESM with the ESM connections in a delta configuration proceed as follows:
CAUTION
(1) To configure the ESM connections in a delta configuration proceed as follows:
a. From the installation kit, obtain the Delta Links to secure to the terminal studs as
detailed in the following steps.
b. From the installation kit, obtain the Terminal Assembly Aid E00002759. This will be
used to determine the height of the Delta Link connections. Attach the Terminal
Assembly Aid to the rear of the motor adjacent to terminal U2 (Fig 11).
c. From the installation kit, fit a single terminal nut to the terminal marked U1 (Fig 11)
running the nut down until it touches the Terminal Installation Aid. Repeat the process
for terminals U2, V1, V2 , W1 and W2.

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ESM
Terminal Pin U1
Terminal Pin U2
Nut M12
Tab Washers
Crimp
Delta Link
Terminal Pin V1
Terminal Pin W2
Terminal Pin V2
Terminal Pin W1
Fig 11 ESM Delta Links
d. Fit an unused tab washer (Fig 11) from the installation kit to the terminals marked U1,
U2, V1, V2, W1 and W2.
e. Fit the three delta links between the terminals marked U1 to W2, W1 to V2 and V1 to
U2.
f. Fit an unused tab washer from the installation kit over the terminals marked U1, U2, V1,
V2, W1 and W2.
g. Fit the remaining terminal nuts to the terminals marked U1, U2, V1, V2, W1 and W2,
tightening finger tight until no clearance remains in the bolted connections (Fig 12).

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ESM
Terminal Pin U1
Folded Tab
Terminal Pin U2
Crimp
Delta Link
Terminal Pin V1
Terminal Pin V2
Terminal Pin W1
Terminal Pin W2
Fig 12 ESM Delta Links Fitted
WARNING
(2) Using a suitable lifting device offer the ESM to the installation site.

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CAUTION
EQUIPMENT DAMAGE. The secondary support fixture must ONLY be used as a means of
levelling the ESM position. It is not designed to take the full weight of the ESM. The M8
NOTE
An M8 eyebolt fitted to the top of the ESM is provided as a lifting aid. The ESM also has 4
handling feet fitted with 1/4-28-UNJF-3B Keensert Helicoils which can be used in conjunction
with the eyebolt to move the ESM into position.
(3) Align the locating dowel fitted to the ESM pad face at 3 o’clock (when viewed from shaft
end) with the hole in the Gas Turbine pad face.
(4) Interface the end of the ESM rotor shaft with the Gas Turbine using the locating dowel as an
alignment aid.
(5) For the industrial Trent and RB211-H63 installations, secure the ESM to the Gas Turbine
using a V band clamp. For RB211-24G(T) installations, secure the ESM using a set of
retaining bolts.
(6) Remove the shipment blanking plugs from the oil inlet and oil outlet ports.
(7) Connect the incoming oil supply pipe to the oil inlet port on the top of the ESM as shown in
Fig 13.
Fig 13 ESM oil system ports
(8) Connect the oil outlet pipe to the oil drain port at the base of the ESM as shown in Fig 13.
(9) Connect the oil breather pipe to the vent at the top of the ESM as shown in Fig 13.

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WARNING

ALL UNITS.
(10) Connect a suitably sized Earth Strap between one of the earth connection points on the
ESM casing and the installation site earth fixing point. The location of the ESM earth
connection points is shown in Fig 16 (Chap 3).
(11) Before commencing any further work on the ESM installation, conduct an earth bonding test
between the ESM body and the installation site earth. Confirm that the measured resistance
is less than 5mΩ.
(12) To connect the cable assembly to the ESM terminals, the ESM installation kit E00002073
will be required.
(13) Remove the cable gland nuts, washers and seals from the rear protective cowl refer to
Fig 10.
(14) Pass the ends of the two power cables from the cable assembly kit through the cable gland
nuts, washers and seals and through the two gland bosses in the rear terminal cowl. Ensure
the cowl earth stud is oriented at the bottom of the assembly.
(15) Cut the cables to length.
(16) Remove sufficient insulation from the outer sheath of each power cable to allow the inner
cores and earth screens to be made off. The outer insulation should not be cut further than
the positions of the cable gland nuts when the cowl is installed.
(17) On each power cable unravel cable screens and twist strands together to form a single core
for each power cable.
(18) Remove sufficient insulation from the inner cores to enable the crimp connections to be
made without leaving conductors exposed after crimping.
(19) Using the M12 crimps from the cable assembly kit make off the crimp connections to the
three power cores for each of the two power cables.
(20) Using the M6 crimps from the cable assembly kit make off the crimp connections for the
three earth cores for each of the two power cables and the earth screen for each of the two
power cables.
(21) Fit heatshrink sleeving over each cable screen and shrink onto the screens.
CAUTIONS
(22) The two power cables to the ESM have a minimum bend radius. For final assembly of the
ESM there must be sufficient length in both power cables to ensure the minimum bend
radius of the power cable is not compromised.
(23) The power cables must be externally supported as close to the ESM as possible. This is
necessary to prevent excessive loads being applied to the ESM cowl, terminal pins and
mounting flange.

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CAUTIONS
(24) Terminate the inner cores to the ESM terminals in accordance with Fig 14, Fig 32 and the
Cable Data Sheets provided in Table 5:
a. Remove an unused tab washer from over the terminals marked U1, U2, V1, V2, W1
and W2.
b. Remove the terminal nuts from the terminals marked U1, U2, V1, V2, W1 and W2.
c. Fit one M12 crimp against the delta links to the terminals marked U1, U2, V1, V2, W1
and W2, Fig 14, Fig 32 and the Cable Data Sheets provided in Table 5.
U1 V1 W1 W2 U2 V2
G1 G1 G1 G3 G2 G2 G2 G3
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
Green/Yellow
(Screen)
(Screen)
Brown
Brown
Black
Black
Grey
Grey
Power Power
cable 1 cable 2
Fig 14 ESM connections – delta configuration
CAUTION
EQUIPMENT DAMAGE. Ensure the M12 crimped power cores are fitted using the installation
aid. If fitted incorrectly shorting to the cowl may occur.
d. Ensure that each power core crimp body is facing in the direction indicated in Fig 15.
CAUTION
e. Ensure there is a minimum clearance of 13 mm between adjacent terminals (Fig 15).

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Minimum
clearance
13mm
U1
Minimum
G1 clearance
13mm
W2 U2
G3
W1 V1
G2
V2
Fig 15 ESM terminal clearance and ESM crimp arrangement – delta configuration
f. Refit the tab washer and nut removed in step a & b to the terminals marked U1, U2, V1,
V2, W1 and W2.
g. Using a 19 mm spanner hold the motor side nut stationary and tighten the other nut to a
torque of 25 Nm (18.4 lbf).
h. Using pliers fold one of the tabs on each washer towards the delta link.
CAUTION
i. Using pliers fold the remaining straight tab (Fig 12) on each washer against its adjacent
nut to prevent loosening of the connection under vibration.
j. Fit the three M6 crimped earth cores from power cable 1 to earth location G1 (refer to
bolt, plain washer and spring washer. Ensure angle position washer is located correctly
as shown in Fig 8.
k. Fit the three M6 crimped earth cores from power cable 2 to earth location G2 (refer to
bolt and plain washer. Ensure angle position washer is located correctly as shown in
Fig 8.
l. Fit two M6 crimped screens to earth location G3 (refer to Fig 14, Fig 32 and the Cable
Data Sheets provided in Table 5) and secure using an M6 bolt and plain washer.
Ensure angle position washer is located correctly as shown in Fig 8.

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m. Ensure that each earth core crimp body is facing in the direction indicated in Fig 15.
CAUTION
n. Ensure there is a minimum clearance of 13 mm between adjacent terminals (Fig 15).
o. Using a 10 mm spanner tighten the M6 bolt secure 3 earth core crimps from power
cable 1 to G1, 3 earth core crimps from power cable 2 to G2 and the 2 earth screens to
G3 to a torque of 15.0 Nm (11.1 lbf).
(25) Connect the interface cable to the signal connector on the top of the ESM, refer to Fig 16,
Fig 32 and the Cable Data Sheets provided in Table 5.
SIGNAL Connector
(26) Before fitting the cowl, ensure that sufficient power cable length is retained to reach the
ESM and to maintain the correct power cable bend radius.

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CAUTIONS
(27) Use the six M6 socket head cap screws from the protective cowl kit to secure the cowl to the
ESM.
(28) Fit cable gland seal, washer and gland nut. Tighten gland nut to fully seal the cable cores.
ESM
M6 Hex Head
Screws (6 off)
Cowl
Cable Glands
(2 off)
Earth Cable
Connections
Fig 17 ESM Cowl Refitting
(29) Remove the earth cable (for cowl to ESM body) and M10 crimps from the installation kit.
(30) Remove sufficient insulation from each end of the earth cable to enable the M10 crimp
connections to be made without leaving conductors exposed after crimping.
(31) Using the M10 crimps from the cable assembly kit make off the crimp connections to each
end of the earth cable.
(32) Connect one end of earth cable to the cowl earth stud using M10 nut, plain washer and
spring washer.
(33) Confirm that the measured resistance between the ESM body and the cowl is less than
5mΩ.

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Electric Start Controller
64 Ensure the following has been completed before commencing installation:
(1) The ESC is fitted with two sets of gland plates (Fig 18), two at the top and two at the bottom,
normally only one set of gland plates are used (top or bottom).
(2) It is the installer’s responsibility to drill the gland plates and supply the cable glands. Ensure
the gland plates have been drilled and have their glands fitted.
Gland Plates M12 Earth Stud
Input busbars
ACH,
Control Interface
Terminal Blocks
Autotransformer
Output busbars
M12 Earth Stud

Gland Plates
Fig 18 ESC

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NOTE
If the bottom gland plates are to be used, ensure the cables for the ESC are fitted in position
under the ESC box structure.
WARNINGS
(3) Ensure that external means of isolating the mains supply to the ESC is provided by the
installer.
(4) Ensure that external means of isolating the ACH supply to the ESC is provided by the
installer.
CAUTION
EQUIPMENT DAMAGE. Correct fuses must be fitted. Fitment of incorrect fuses may result in
damage to the ESC.
(5) Ensure that the mains supply to the ESC is externally fuse protected by the installer. Fuses
must be selected for the appropriate mains supply voltage (i.e. 380V/ 415V/ 440V/ 480V/
600V/ 690V), as selected at the voltage taps on the Auto-Transformer inside of the ESC.
See Table 1 for the supply current at rated continuous load and rated intermittent load (1
minute duration) for the different supplies.
TABLE 1 MAINS SUPPLY FUSING
Supply Rated Continuous Supply Current Rated Intermittent (1 minute duration)

(Amps) Supply Current (Amps)
380V 330 473
415V 314 449
440V 285 408
480V 262 374
600V 210 300
690V 182 260
(6) Ensure that the ACH supply to the ESC is externally fuse protected by the installer. Fuses
must be selected for the appropriate ACH supply voltage (i.e. 110V/ 230V), as selected at
the links inside of the ESC. See Table 2 for supply currents for different supplies.

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TABLE 2 ACH SUPPLY FUSING
Supply ACH Continuous Supply

Current (Amps)
110V 2
230V 1
WARNING
EMERGENCY STOP. THE ELECTRIC START SYSTEM IS NOT FITTED WITH AN

EMERGENCY STOP FACILITY. THIS FACILITY MUST BE SUPPLIED BY ROLLS-ROYCE
(7) Ensure that an Emergency Stop facility is provided by the installer.
(8) Ensure that the correct application code is loaded into the ESC
65 To load the application code into the ESC, proceed as follows:
(1) Contact Ultra Electronics for provision of the application code and instructions for the
loading of the application code into the ESC.
66 Installation should be carried out in accordance with the ESC Installation Diagram E00002754
(Fig 17). To install the ESC proceed as follows:
WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START CONTROLLER IS 1300 KG.
CAUTION
EQUIPMENT DAMAGE. The ESC must only be lifted using the four lifting eyes.
(1) Using a suitable lifting device offer the ESC to the installation site and position in the correct
orientation.
NOTE
The ESC is designed for installation using the four M12 eyebolts fitted to the top of the ESC.
(2) Two M12 earth studs are provided; one at the top of the ESC and one at the bottom of the
ESC. The location of the ESC earth studs are shown in Fig 17 (Chap 3).
WARNING

ALL UNITS.
(3) Connect a suitably sized Earth Strap between one of the M12 ESC earth studs and the
installation site earth fixing point.
(4) Tighten the M12 ESC earth stud nut to a torque of between 35Nm (25.82lbf) and 42Nm
(30.98lbf).

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(5) Before commencing any further work on the ESC installation, conduct an earth bonding test
between the ESC cabinet metalwork and the installation site earth. Confirm that the
measured resistance is less than 5mΩ.
CAUTION
EQUIPMENT DAMAGE. Correct fuses must be fitted. Fitment of incorrect fuses may result in
damage to the ESC.
(6) The following fuses are fitted within the ESC:
TABLE 3 ESC INTERNAL FUSES
Fuse Ref Location/Function Value Type
FS1-6 Autotransformer Secondary 200A A4J200
FS7-9 Pre-Charge & Control Transformer Primary 4A ATQR4
FS10-11 Pre-Load 10A DCT10-2
FS12-17 ESC Output 250A AJT250
FS18 Control Transformer Secondary 4A ATQR4
FS19 ACH 230V 2A ATQR2
FS20 ACH 110V 4A ATQR4
(7) Remove the “weather strip” (see Fig 19) securing the two doors into position by removing
the 14 fixings.

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(8) Using an 8mm Allen key release the two quarter turn fasteners (Fig 19) securing the right
hand door to the ESC. Using the key, unlock the right hand door. Open both doors fully.
¼ Turn Fasteners (2 off)

Weather Strip
Lock
Doors (2 off)
Fig 19 ESC Doors

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(9) The ESC is designed to operate from a range of supply voltages between 380V and 690V
50/60Hz. During installation it is necessary to change the voltage setting on top of the
autotransformer inside the ESC according to the supply specification. Available voltage
settings are as follows:
a. 380V
b. 415V
c. 440V
d. 480V
e. 600V
f. 690V
(10) Each phase of the primary winding of the Hexaphase Autotransformer requires setting to the
correct input voltage. There are six different primary voltages, select the correct voltage tap
as follows:
CAUTION
EQUIPMENT DAMAGE. Connecting the swinging link to an incorrect input voltage tap may
result in excessive voltage and subsequent damage to the equipment.
a. Remove the M10 retaining nuts securing the L1 swinging link to the top of the
Hexaphase Autotransformer, refer to Fig 20.
Swinging
link
Voltage
Taps
Common
Hexaphase Retaining
Autotransformer nuts
Fig 20 Hexaphase autotransformer
b. Remove the L1 swinging link from the top of the Hexaphase Autotransformer.

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c. Refit the L1 swinging link between the correct input voltage tap and the L1 common and
secure using the two M10 retaining nuts – securing the first nut against the nut
underneath the swinging link and the second nut against the first nut. Ensure there are
no nuts or washers in-between the electrical connections.
d. Repeat the procedures described in Para (10)a to (10)c for L2 and L3 swinging links.
e. Tighten the M10 retaining nuts to a torque of between 25Nm (18.44lbf) and 30Nm
(22.13lbf).
(11) Feed the cables through the cable glands on the ESC gland plates.
a. The input supply cables are fed through a right hand gland plate (top or bottom).
b. The output cables are fed through a left hand gland plate (top or bottom).
c. The ACH cable, control interface cable and motor thermistor cable are fed through
either gland plate, whichever is the most appropriate.
(12) Refer to the ESC Installation Diagram (Fig 17) for guidance on the routing of the cables.
(13) Terminate the three-phase mains supply cable cores to the input busbars mounted inside
the ESC in accordance with Fig 21, Fig 32 and the Cable Data Sheets provided in Table 5
as follows:
Input L3 Input L2 Input L1

Busbar Busbar Busbar
Use these holes to

terminate the mains
supply cable cores.
Fig 21 ESC mains supply input busbars

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a. Use an M10 bolt, two M10 plain washers, an M10 spring washer and an M10 nut to
terminate the three-phase mains supply cable cores to the input busbars as shown in
Fig 22. Tighten the M10 retaining nuts to a torque of between 25Nm (18.44lbf) and
30Nm (22.13lbf).
CAUTION
EQUIPMENT DAMAGE. Ensure bolt is fitted with threaded end facing outwards (towards
door) to maintain electrical clearance between busbar and metalwork.
M10 Plain M10 Spring

Washer Washer
M10 Bolt
Busbar
M10 Nut
Cable
Crimp
Fig 22 Cable crimp input busbar
b. Perform a bonding test for each of the three-phase mains cable core connections to
their respective input busbar. Confirm that the measured resistance is less than 5mΩ.
(14) Terminate the anti-condensation heater (ACH) cable cores to the terminal blocks mounted
inside the ESC in accordance with Fig 23, Fig 32 and the Cable Data Sheets provided in
Table 5.
Earth
TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8
Fig 23 ESC ACH connections

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CAUTION
EQUIPMENT DAMAGE. Connecting the ACH supply to an incorrect input voltage
configuration may result in excessive voltage and subsequent damage to the equipment.
NOTE
The ACH supply voltage can be 110V or 230V. Refer to Cable Data Sheets provided in
Table 5 for specific voltage connection details.
(15) Terminate the cables in the terminal blocks (Fig 24) as follows:
2 1
Fig 24 Terminal block connection procedure
a. Introduce the screwdriver at a slightly curved angle into the operating slot (Fig 25) and
push down until stop. See arrow!
Fig 25 Terminal block connection (1)
b. The screwdriver blade holds the clamping spring open automatically (Fig 26). Introduce
the conductor into the clamping unit.

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c. Withdraw the screwdriver – the conductor is automatically clamped (Fig 27).

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(16) Terminate the control and monitor interface cable cores to the terminal blocks mounted
inside the ESC in accordance with Fig 28, Fig 32, the Cable Data Sheets provided in
Table 5 and Paras 66(15)a to 66(15)c.
Terminal blocks Terminal blocks

TB19 to TB 35 Screen Earths TB36 to TB 62
Fig 28 ESC control and monitor interface connections
(17) Terminate the signal interface cable cores to the terminal blocks mounted inside the ESC in
accordance with Fig 28, Fig 32, the Cable Data Sheets provided in Table 5 and Paras
66(15)a to 66(15)c.

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(18) Terminate the three-phase output power cores (fitted with M10 crimps) for each of the
output power cables to the output busbars mounted inside the ESC in accordance with
Fig 29, Fig 32 and the Cable Data Sheets provided in Table 5 as follows:
Fig 29 ESC three-phase output cable connections
a. Use a M10 bolt, two M10 plain washers, a M10 spring washer and a M10 nut to
terminate the three-phase output cable cores to the output busbars as shown in Fig 30.
CAUTION
EQUIPMENT DAMAGE. Ensure bolt is fitted with threaded end facing outwards (towards
door) to maintain electrical clearance between busbar and metalwork.
M10 Plain M10 Spring

Washer Washer
M10 Bolt
Busbar
M10 Nut
Cable
Crimp
Fig 30 Cable crimp output busbar

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b. Perform a bonding test for each of the output power cable core connections to their
respective output busbar. Confirm that the measured resistance is less than 5mΩ.
(19) Terminate the three earth cores and the screen (each fitted with an M8 crimp) from each of
the three the output power cables to the earth busbar (fitted with M8 fixings) mounted inside
the ESC in accordance with Fig 29, Fig 32 and the Cable Data Sheets provided in Table 5.
(20) Close the two front doors and using an 8 mm Allen key secure the two quarter turn
fasteners (Fig 19). Using the key, lock the two front doors.
(21) Fit the “weather strip” (see Fig 19) securing the two doors into position using the 14 fixings.
WARNING
ENCLOSURE RATING. THE CONTROLLER IP52 ENCLOSURE RATING IS ONLY ACHIEVED

WITH THE WEATHER STRIP FITTED ON THE DOORS
JUNCTION BOX
67 The Junction Box is used to make a transition from a normal environment to the higher temperature
environment within the engine enclosure. The junction box is mounted on the outside of the enclosure.
68 The Junction Box is a box structure with a removable front panel. Electrical connection to the Junction
Box is via cable glands mounted on gland plates on either side of the Junction Box. Electrical termination
is to terminal blocks mounted on a rail inside the Junction Box. The Junction Box is mounted using four
mounting lugs, two at the top and two at the bottom (Fig 31).
Earth stud
Gland Gland
Plate Plate
Mounting feet
Earth stud
Fig 31 Junction Box

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69 Installation Instructions for ATEX-Certified NXT Range Enclosures
(1) The installation instructions listed below have been based on the following documents;
a. EEx e Component Certificates for enclosures,
b. EN 60079-14 – Electrical installations in hazardous areas,
c. BS 5345 – parts 1, 4, & 6 – Code of Practice for selection, installation & maintenance,
d. Established installation / engineering practice.
(2) Alterations or modifications to the enclosure may invalidate the certification.
(3) Observe information marked on the certification label, e.g. Type/s of Protection.
(4) Observe the maximum or minimum ratings specified in the certificate.
(5) Enclosures assigned an impact level of 4J or 4Nm must be installed only in areas of ‘low
mechanical danger’.
(6) Cable glands and stopping plugs must be suitable for the application and must maintain a
minimum degree of protection of IP54 for use in gas / vapour atmospheres (EEx e), and
IP6X for use in dust atmospheres.
(7) The installer is permitted to drill entries in areas specified on the certified drawings.
(8) Where a metal cable gland is fitted through a clearance hole in an earth continuity plate, a
locknut must be fitted on each side of that plate. Alternatively, the gland can be screwed
into a threaded hole in the plate and secured with a locknut. Individual plates must be
bonded together.
(9) Where a gland plate is provided with an auxiliary earthstud, it shall be connected to the main
enclosure earthstud with an appropriately sized conductor.
(10) External identification labels may be fitted by the installer and must maintain a minimum
degree of protection of IP54 for use in gas / vapour atmospheres (EEx e), and IP6X for use
in dust atmospheres.
(11) Ensure that all lid and gland plate screws are fully tightened after installation.
(12) The marking for external certification label is as shown.

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NXT RANGE ENCLOSURES
II 2 G EEx e II
1180
II 2 D IP 66
No. KEMA99ATEX3174U
YEAR OF CONSTRUCTION 2004
70 Installation instructions for installing cables into the junction box:
(1) Use Table 4 to aid in locating the position of the power cables along with the instructions
below. The terminal blocks are numbered from 1 to 17.
a. Terminals 1 to 2 are UT16 terminals.
b. Terminals 3 to 8 are UK150 terminals.
c. Terminals 9 to 14 are UT16 terminals.
d. Terminals 15 to 17 are UT2.5 terminals.
(2) Installation of cables from ESC
a. Fit a suitably sized external earth strap to either of the two external junction box earth
studs.
b. Remove the junction box cover by releasing the self retaining screws.
c. Drill the right hand gland plate and install suitable cable glands (provided by the
installer) for the two power cables and the signal cable from the ESC.
d. Terminate the power cable 1a power cores L1, L2 and L3 to the grey UK150 terminal
blocks as detailed in Table 4. Use a flat head screwdriver to tighten the terminal to
25Nm
e. Terminate the power cable 1b power cores L1, L2 and L3 to the grey UK150 terminal
25Nm.
f. Terminate the power cable 1a earths (3 off) to the grey UT16 terminal blocks as
detailed in Table 4. Use a flat head screwdriver to tighten the terminal.
g. Terminate the power cable 1b earths (3 off) to the grey UT16 terminal blocks as
h. Terminate the screens of both power cable 1a and 1b to the terminal blocks UT16 as
detailed in Table 4.
i. Terminate signal cable 1 cores and screen using terminal blocks UT2.5 as detailed in
Table 4.
j. Complete installation of the cable glands (provided by the installer) according to the
manufacturer’s instructions.
(3) Installation of cables from motor
a. Drill the left hand gland plate and install suitable cable glands (provided by the installer)
for the two power cables and the signal cable from the ESM.

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b. Terminate the power cable 2a power cores L1, L2 and L3 to the grey UK150 terminal
25Nm
c. Terminate the power cable 2b power cores L1, L2 and L3 to the grey UK150 terminal
25Nm
d. Terminate the power cable 2a earths (3 off) to the grey UT16 terminal blocks as
e. Terminate the power cable 2b earths (3 off) to the grey UT16 terminal blocks as
f. Terminate the screens of both power cable 2a and 2b to the terminal blocks UT16 as
detailed in Table 4.
g. Terminate signal cable 2 cores and screen using terminal blocks UT2.5 as detailed in
Table 4.
h. Complete installation of the cable glands (provided by the installer) according to the
manufacturer’s instructions.
i. After installing the cables, ensure that the earth studs on the cover and the two gland
plates are connected to the internal junction box earth stud using suitably sized
conductors.
j. Replace the cover onto the junction box and secure using the self retaining bolts.
TABLE 4 JUNCTION BOX TERMINAL BLOCKS
Terminal Cable and core (ESC side) Cable and core (ESM side)
Ref
1 Power Cable 1a, Screen Power Cable 2a, Screen
2 Power Cable 1b, Screen Power Cable 2b, Screen
3 Power Cable 1a, Core L1 Power Cable 2a, Core L1
6 Power Cable 1b, Core L1 Power Cable 2b, Core L1
9 Power Cable 1a, Earth Core Power Cable 2a, Earth Core
12 Power Cable 1b, Earth Core Power Cable 2b, Earth Core

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15 Signal cable 1 core Signal cable 2 core
16 Signal cable 1 core Signal cable 2 core
17 Signal cable 1 screen Signal cable 1 screen

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Supplies 1
Electric Electric
Junction
Start 3 4 Start
Box
Controller Motor
Control
Monitor 2
Interface
Fig 32 Group cabling diagram

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TABLE 5 CABLE DATA SHEETS
GROUP No. CABLE TYPE (NSN) O/D (mm) LENGTH (mm) CABLE No.
1 X X X 1
EQUIPMENT A NAME EQUIPMENT B NAME
Installation Supplies Electric Start System
UNIT A NAME UNIT B NAME
X Electric Start Controller
UNIT A LOCATION UNIT B LOCATION
X X
CONNECTOR DETAILS ENTRY CONNECTOR DETAILS ENTRY
X X X Gland
R CORE UNIT A FUNCTION UNIT B TERM. C
E IDENT. TERM H
V K
L1 380V - 690V 50/60Hz “Input L1” Busbar
L2 Three-Phase “Input L2” Busbar
L3 Mains Supply “Input L3” Busbar
NOTE
Each phase of the primary winding of the Hexaphase Autotransformer
requires setting to the correct input voltage. There are six different
primary voltages, select the correct voltage tap as described in
Para 66(8).

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TABLE 5 CABLE DATA SHEETS (continued)
1 X X X 2
Installation Supplies Electric Start System
X X
X X X Gland
R CORE UNIT A FUNCTION UNIT B C
E IDENT. TERM TERM. H
V K
L 110V or 230V 60 Hz See Note
N Single-Phase ACH Supply TB1
E Earth E101
NOTE
The ACH supply voltage can be 110V or 230V:
For 110V connect L to TB4, connect a link between TB7 and TB8.
For 230V connect L to TB3, connect a link between TB6 and TB7.

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2 X X X 1
Installation Control and Monitoring Interface Electric Start System
X X
X X X Gland
V K
Ready/Tripped Common  TB21
Ready/Tripped NO | TB22
Normal/Alarm Common | TB23
Normal/Alarm NO | TB24
Cable Screen ⌡ E102
Speed Input 4-20mA +ve  TB36
Speed Input 4-20mA –ve | TB37
Power Input 4-20mA +ve | TB38
Power Input 4-20mA –ve | TB39
Enable/Disable  TB26
+24V Enable/Disable | TB25
Start/Stop | TB28
+24V Start/Stop | TB25
Speed Mode/Power Mode | TB29
+24V Speed Mode/Power Mode | TB25
Speed Indication 4-20mA +ve  TB40
Speed Indication 4-20mA -ve | TB41
Power Indication 4-20mA +ve | TB42
Power Indication 4-20mA -ve | TB43
Devicenet -ve  TB46
Devicenet CAN_L | TB47
Devicenet CAN_H | TB48
Devicenet +ve | TB49

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3 X X X 1
Electric Start System Electric Start System
Electric Start Controller Junction Box
X X
X Gland X Gland
V K
TB44 Motor Thermistor +ve 15
TB45 Motor Thermistor -ve 16
Earth stud Screen 17

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3 X 42.6 Up to 100m 2
X X
X Gland X Gland
R CORE UNIT A TERM FUNCTION UNIT B TERM. C
E IDENT. H
V K
Bn “Output L1” Busbar L1 Variable Voltage 3
Bk “Output L2” Busbar L2 Variable Frequency 4
Gy “Output L3” Busbar L3 Drive to Motor (Cable 1A) 5
Gr/Yw Busbar Earth 1 (See Note) Earth 9
Busbar Earth 2 (See Note) Screen 1
NOTE
All connections to earth bar studs local to output busbars.

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3 X 42.6 Up to 100m 3
X X
X Gland X Gland
R CORE UNIT A TERM FUNCTION UNIT B TERM. C
E IDENT. H
V K
Bn “Output L1” Busbar L1 Variable Voltage 6
Bk “Output L2” Busbar L2 Variable Frequency 7
Gy “Output L3” Busbar L3 Drive to Motor (Cable 1B) 8
Busbar Earth 4 (See Note) Screen 2
NOTE
All connections to earth bar studs local to output
busbars.

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4 X X X 1
Junction Box Electric Start Motor
X X
X Gland X Gland
V K
15 Motor Thermistor +ve SIG_1
16 Motor Thermistor -ve SIG_2
17 Screen Shell

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4 X 35.2 Up to 10m 2
X X
X Gland M12 Crimp, M6 Crimp Gland
R CORE UNIT A TERM FUNCTION UNIT B C
E IDENT. TERM. H
V K
Bn 3 L1 Variable Voltage U1
Bk 4 L2 Variable Frequency V1
Gy 5 L3 Drive to Motor (Cable 2A) W1
Gr/Yw 9 Earth G1
Gr/Yw 10 Earth G1
Gr/Yw 11 Earth G1
1 Screen G3
NOTE
This cable data sheet is for the ESM when connected in a Star
Configuration on the industrial Trent gas turbine only

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4 X 35.2 Up to 10m 3
X X
E IDENT. TERM. H
V K
Gy 8 L3 Drive to Motor (Cable 2B) W1
Gr/Yw 12 Earth G2
Gr/Yw 13 Earth G2
Gr/Yw 14 Earth G2
2 Screen G3
NOTE
Configuration on the industrial Trent gas turbine only

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4 X 35.2 Up to 10m 3
X X
E IDENT. TERM. H
V K
Gy 5 L3 Drive to Motor (Cable 2A) W1
Gr/Yw 9 Earth G2
Gr/Yw 10 Earth G2
Gr/Yw 11 Earth G2
1 Screen G3
NOTE
This cable data sheet is for the ESM when connected in a Delta
Configuration on the industrial RB211-24G(T) gas turbine only

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4 X 35.2 Up to 10m 3
X X
E IDENT. TERM. H
V K
Bn 6 L1 Variable Voltage W2
Bk 7 L2 Variable Frequency U2
Gy 8 L3 Drive to Motor (Cable 2B) V2
Gr/Yw 12 Earth G2
Gr/Yw 13 Earth G2
Gr/Yw 14 Earth G2
2 Screen G3
NOTE
This cable data sheet is for the ESM when connected in a Delta
Configuration on the industrial RB211-24G(T) gas turbine only

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4 X 35.2 Up to 10m 3
X X
E IDENT. TERM. H
V K
Gy 5 L3 Drive to Motor (Cable 2A) U1
Gr/Yw 9 Earth G2
Gr/Yw 10 Earth G2
Gr/Yw 11 Earth G2
1 Screen G3
NOTE
Configuration on the industrial RB211-H63 gas turbine only

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4 X 35.2 Up to 10m 3
X X
E IDENT. TERM. H
V K
Gy 8 L3 Drive to Motor (Cable 2B) U2
Gr/Yw 12 Earth G2
Gr/Yw 13 Earth G2
Gr/Yw 14 Earth G2
2 Screen G3
NOTE
Configuration on the industrial RB211-H63 gas turbine only

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CHAPTER 5
MAINTENANCE INSTRUCTIONS
CONTENTS
Page
Introduction 3
Diagnostic maintenance 3
Control and Monitoring Interface 3
System Fault Diagnosis 4
Corrective maintenance 10
ESM 10
ESM with Star Configuration 13
ESM with Delta Configuration 13
ESC 14
Drive Module 14
Control Module 19
Cubicle Cooling Fan 24
Drive Module Cooling Fan 27
Soft Start Contactor 33
Fan Filter 35
Fuses 38
Junction Box 44
Preventive maintenance 45
ESM 45
Oil Connection Inspection 45
Earth Bonding Continuity 46
ESC 47
Earth Bonding Continuity 47
Air Cooling Filter Element Renewal 48
Drive Module Cooling Fan Renewal 49
Cubicle Cooling Fan Renewal 50
In Storage Maintenance 51
Bar Over Motor 51
Capacitor Charging 51
TABLES
Page
Table 1 Fuses 3
Table 2 Devicenet Fault Codes 4
Table 3 fault finding against devicenet fault codes 5
FIGURES
Page
Fig 2 ESM oil system 12
Fig 3 ESC Doors 15
Fig 4 Fan Baffle 16
Fig 5 Drive module 17

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FIGURES
Page
Fig 6 Control Module – 1 20
Fig 10 Option Board A8 – Jumper Settings 23
Fig 11 Fan Assembly 25
Fig 12 Fan Terminal Block 25
Fig 13 ESC – Fan Fixings 26
Fig 14 Drive Module Cooling Fan – 1 28
Fig 22 Soft Start Contactor (CTR3) 34
Fig 23 ESC bottom air vent 35
Fig 24 ESC top air vent 36
Fig 25 ESC top air vent 36
Fig 26 ESC Fuses FS7 to FS9 39
Fig 28 ESC Fuse FS18 40
Fig 30 ESC Fuses FS7 to FS11 and FS18-20 – Fuseholder 41
Fig 31 ESC Output fuses FS12 to FS17 42
Fig 32 ESC Input fuses FS1 to FS6 43
Fig 33 Oil connections - ESM 45
Fig 34 Drive Module DC Power Supply Connections 52

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INTRODUCTION
1 The overall repair policy for the Electric Start System (ESS) is one of direct replacement of major
items.
DIAGNOSTIC MAINTENANCE
CONTROL AND MONITORING INTERFACE
2 The Electric Start Controller (ESC) provides an electrical interface allowing external control and
monitoring of the ESS condition. The ESC control and monitoring interface provides the following signal
interfaces:
(1) Ready/Tripped
(2) Normal/Alarm
(3) Speed Input
(4) Power Input
(5) Enable/Disable
(6) Start/Stop
(7) Speed Mode/Power Mode
(8) Speed Indication
(9) Power Indication
(10) DeviceNet
3 The ESC is fitted with fuses; Table 1 identifies the function of each fuse.
TABLE 1 FUSES
Fuse Rating Function

FS1 200A Protects the L1-1 phase of T1 secondary to L1.
FS7 4A Protects the L1 phase of the ac supply to T2 primary and rectifier D3.
FS8 4A Protects the L2 phase of the ac supply to T2 primary and rectifier D3.
FS9 4A Protects the L3 phase of the ac supply to rectifier D3.
FS10 10A Protects the dc supply from rectifier D3 and resistor R1 to the Drive Module.

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Fuse Rating Function

FS11 10A Protects the dc supply from rectifier D3 and resistor R1 to the Drive Module.
FS12 250A Protects the ESC output L1.
FS18 4A Protects the 230V 60Hz supply input from transformer T2.
FS19 2A Protects the 230V 60Hz ACH supply.
FS20 4A Protects the 110V 60Hz ACH supply.
SYSTEM FAULT DIAGNOSIS
4 System fault diagnosis is carried out via the DeviceNet interface.
5 If the ESC develops a fault, consult the following table if the DeviceNet Fault Code is known.
TABLE 2 DEVICENET FAULT CODES
DeviceNet Fault Code Vacon NX Fault Code

Hex 2300 F1 Over Current
Hex 3210 F2 Voltage
Hex 2330 F3 Earth fault
Hex 5420 F4 Inverter Fault
Hex 5120 F5 Charging Switch
Hex 3220 F9 Under Voltage
Hex 3130 F10 Input Phase Supervision
Hex 3130 F11 Output Phase Supervision
Hex 7111 F12 Brake Chopper Supervision
Hex 4210 F13 Vacon Under Temperature
Hex 4220 F14 Vacon Over Temperature
Hex 7120 F15 Motor Stalled
Hex 7120 F16 Motor Over Temperature
Hex 7120 F17 Motor Under Load
Hex 7600 F22 EEPROM Checksum Fault
Hex 6010 F25 Microprocessor Watchdog

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DeviceNet Fault Code Vacon NX Fault Code

Hex 5000 F32 Fan Cooling
Hex 5200 F36 Control Unit
Hex 6100 F37 Device Change
Hex 6100 F38 Device Added
Hex 6100 F39 Device Removed
Hex 6100 F40 Device Unknown
Hex 2300 F41 IGBT Temperature
Hex 1000 F42 Brake Resistor Overtemp
Hex 5200 F50 Analog Input Iin < 4mA
Hex 9000 F51 External Fault
Hex 7510 F52 Keypad Communication Error
Hex 1000 Unknown Fault
Hex 0000 No Fault
6 Table 3 lists the possible faults and trouble shooting actions against each DeviceNet Fault Code.
TABLE 3 FAULT FINDING AGAINST DEVICENET FAULT CODES
Fault Description Problem Action Paragraph

Hex Drive over current in motor Sudden heavy load Check motor loading -
2300 cables increase
Check motor by performing -
an insulation test and
check the motor is not
binding.
Short circuit in Check that ESC output is -
motor cables not short circuited
Check motor cables -
Hex Drive DC link Over Voltage Deceleration time Check motor loading -
3210 too short
Over voltage on Check for voltage -
supply to ESC transients on the ac supply
Check ac supply is within -
the +/-5% tolerance of tap
setting
Incorrect tap setting Check the correct links are -
fitted on the
autotransformer.
Hex Earth Fault Insulation failure in Check motor cables -
2330 motor or cables
Check motor by performing -
an insulation test
Hex Inverter Fault Fault with Drive Replace Drive Module LRU Para 16
5420
Replace Control Module Para 25
LRU

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Hex Charging Switch Fault with Drive Reset the fault and restart -
5120
If fault persists, replace Para 16
Drive Module LRU
Control Module LRU
Hex Drive DC link Under Under voltage on Check for voltage dips on -
3220 Voltage supply to ESC the ac supply
Check ac supply is within -
the +/-5% tolerance of tap
setting
fitted on the
autotransformer.
Fault with Drive Reset the fault and restart -

Drive Module LRU
Control Module LRU
Hex Input Phase Supervision: AC supply phase is Check ac supply cables -
3130 missing
Supply voltage fault Check ac supply voltage -

fitted on the
autotransformer.
Hex Output Phase Supervision: ESC output phase Check motor cables -
3130 is missing
Check motor
Hex Brake Chopper Supervision N/A external - -

7111 chopper
Hex Vacon Under Temperature Ambient Check ESC location -
4210 temperature too ambient is above -10°C.
low
Fault with Drive Reset the fault and restart -

Drive Module LRU
Control Module LRU
Hex Vacon Over Temperature: Ambient Check ESC location -
4220 Vacon drive temperature temperature is too ambient is below 40°C
has exceeded 90°C high
ESC cabinet air Remove ESC cabinet air
vents are blocked vent blockage(s).
ESC cabinet air Replace ESC cabinet air Para 31
filters are blocked filter(s)
ESC cabinet fans Replace ESC cabinet Para 22
have failed fan(s)
Hex Motor Fault: (F15) Motor Motor stall Check Motor is not binding. -
7120 stalled protection has
tripped

UNCLASSIFIED

Hex Motor Fault: (F16) Motor Motor ambient Check Motor location -
7120 over-temperature temperature is too temperature is below
high 100ºC
Motor overloaded Check Motor loading -
Motor fault Check Motor is not binding -

and test insulation.
Faulty oil cooling Check Motor oil cooling -
circuit circuit
Hex Motor Fault: (F17) Motor Incorrect loading Check Motor loading -
7120 under load
Hex EEPROM Checksum fault Fault with drive Replace Drive Module LRU Para 16
7600
Hex Microprocessor watchdog Fault with drive Reset the fault and restart -
6010
Drive Module LRU
Control Module LRU
Hex Fan Cooling Drive cooling fan Replace Drive Module Para 25
5000 failure Cooling Fan
Hex Control Unit fault Loose/broken Check connections from -

5200 connection Drive Module to Control
between Drive and Module.
ESC
Faulty ESC unit Replace Control Module Para 19
LRU
Hex Device Changed (F37) Control Module Reset fault and restart -
6100 LRU replaced
Drive Module LRU Reset fault and restart -
replaced
Hex Device Added (F38) Control Module Reset fault and restart -
6100 LRU replaced
replaced
Hex Device Removed (F39) Control Module Reset fault and restart -
6100 LRU replaced

replaced
Hex Device Unknown (F40) Unknown board or Replace Control Module Para 19
6100 drive LRU
Replace Drive Module LRU Para 16
Hex IGBT over-temperature Due to a high short Check motor by testing -

2300 term over-current insulation.
Check motor loading -
Hex Brake resistor over- Deceleration too Feature not enabled -

1000 temperature fast

UNCLASSIFIED

Hex Current at analogue input is Control cable is Check connections from -
5200 below <4mA broken or loose Drive Module to Control
Module.
Signal source has Replace Control Module Para 16
failed LRU
Hex External fault Temperature relay Check state of temperature -

9000 tripped relays.
Faulty connection Check connections of -

to temperature temperature sensors to
sensors drive.
Hex Keypad communication Connection Keypad not enabled -

7510 fault between ESC and
keypad is broken
Hex Unknown fault Contact Ultra Electronics -
1000
Hex No Fault Drive is functioning No action required -
0000 correctly, no action
needs to be taken
FS53 Devicenet communication Faulty interface Check connections -
failure cable to Control between engine interface
Module and Control Module
Faulty ESC Replace Control Module Para 19
LRU
ESC ESC cabinet light does not 380 to 690V Check supply -
light illuminate 50/60Hz supply is
not present
ACH ACH cabinet light does not 120/240V 60Hz Check ACH supply cables -
light illuminate supply is not
connected or
operational
ESM ESM does not start when System Check system installation -
commanded interconnections (ESC, cables, Junction Box
are incorrect and Motor)
Signal interface is Check interface to engine -
not connected management system
Emergency Stop is Reset Emergency Stop -
activated
ESM Phase rotation is incorrect System Check system installation -
interconnections (ESC, cables, Junction Box
are incorrect and Motor)
Incorrect Check correct application -
application code is code is installed for the
installed engine type
ESM Oil leakage at the ESM Faulty labyrinth Replace Motor LRU Para 9
seal at DE of ESM
Faulty ‘o’ ring seal Replace Motor LRU Para 9
at NDE of ESM
Oil inlet and outlet Remake oil connections -
pipes not fitted
correctly
ESM Excessive ESM Vibration Premature rotor / Replace Motor LRU Para 9
bearing failure
ESM Excessive ESM Noise Premature rotor / Replace Motor LRU Para 9
bearing failure

UNCLASSIFIED

ESM Broken Shear Neck in Motor overloaded Check motor load -
Gearbox
Motor seizure Replace Motor LRU Para 9

UNCLASSIFIED
CORRECTIVE MAINTENANCE
7 The following paragraphs detail the removal and replacement procedures for the line replaceable
units within the ESS.
ESM
8 Tools required:
(1) Allen Key: 6 mm
(2) Spanner: 10 mm, 2 off 19 mm
(3) Pliers
9 The ESM is an LRU, to remove the ESM proceed as follows:
WARNINGS

EMPLOYED.
9.1 Isolate the 380-690V 50/60 Hz three-phase mains supply to the ESC at the external isolator
and lock out.
9.2 Isolate the 110V/230V 60Hz single-phase ACH supply to the ESC at the external isolator
and lock out.
9.3 Disconnect the connector from the SIGNAL connector on the ESM casing as shown in Fig 1,
coil back the cable and tie out of the way.

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SIGNAL Connector
9.4 Release the two cable gland nuts on the cowl.
9.5 Remove the six M6 socket head cap screws securing the cowl to the rear of the ESM.
9.6 Carefully slide the cowl away from the rear of the ESM.
9.7 Disconnect the cable cores from the terminals at the rear of the ESM, noting connection
details for subsequent reconnection. If cables are not fitted with indent sleeves or any other form of
marking, mark conductors appropriately and record markings.
9.8 Isolate the oil supply to the ESM.
WARNING
OIL SPILLAGE. DISCONNECTING THE OIL INLET AND OUTLET PIPES WILL CAUSE OIL
SPILLAGE. ENSURE THAT AN OIL SPILL KIT IS AVAILABLE DURING THIS PROCEDURE.
9.9 Disconnect the incoming oil supply pipe from the oil inlet port on top of the ESM as shown in
Fig 2.

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Fig 2 ESM oil system
9.10 Disconnect the oil outlet pipe to the oil drain port at the base of the ESM as shown in Fig 2.
9.11 Disconnect the oil breather pipe (if used) from the oil vent on top of the ESM as shown in
Fig 2.
9.12 Remove magnetic plug and inspect for debris. If debris exists then carefully scrape it off the
plug and retain for analysis.
9.13 Refit the magnetic plug to the ESM.
9.14 Disconnect the Site Installation Earth Strap from the earth connection point on the ESM
casing.
9.15 Disconnect the cowl Earth Strap from the earth connection point on the ESM casing.
9.16 Using a suitable lifting device support the ESM then remove the V band clamp or retaining
bolts securing the ESM to the Gas Turbine.
WARNING
9.17 Using a suitable lifting device slide the ESM away from the Gas Turbine and remove the
ESM from the installation site.
10 Before refitting an ESM ensure the following items are available:
(1) ESM installation kit E00002703
11 Before the new ESM is installed the ESM connections must be configured. The ESM connections can
be configured as a star connection or as a delta connection.

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(1) The star connection is required for the industrial Trent 60 and RB211-H63 Gas Turbines; to
install the ESM with the ESM connections in a star configuration refer to Para 12.
(2) The delta connection is required for the RB211-24G(T) Gas Turbine; to install the ESM with
the ESM connections in a delta configuration refer to Para 13.
ESM with Star Configuration
12 To install the ESM with the ESM connections in a star configuration, follow the procedures detailed in
Chapter 4 pages 12 to 23.
ESM with Delta Configuration
13 To install the ESM with the ESM connections in a delta configuration, follow the procedures detailed
in Chapter 4 pages 24 to 32.

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ESC
14 The following LRUs form part of the ESC.
(1) Drive Module
(2) Control Module
(3) Cubicle Cooling Fan
(4) Drive Module Cooling Fan
(5) Soft Start Contactor
(6) Fan Filter
Drive Module
15 Tools required:
(1) Allen Key: 8 mm
16 To remove the Drive Module proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING
LETHAL VOLTAGE. WAIT FIVE MINUTES BEFORE OPENING ELECTRIC START

CONTROLLER DOORS
16.3 Wait for a minimum of five minutes before opening the cabinet after power supplies have
been removed.
16.4 Remove the “weather strip” (see Fig 3) securing the two doors into position by removing the
14 fixings

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16.5 Using an 8 mm Allen key release the two quarter turn fasteners (Fig 3) securing the right
¼ Turn Fasteners (2 off)

Weather Strip
Lock
Doors (2 off)
Fig 3 ESC Doors

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16.6 Disconnect the power cables from terminals B+ and B- at the top of the drive module.
16.7 Remove the output power cables from the busbars at the bottom of the drive module.
16.8 Disconnect the fibre optic cables pu1 and pu2 from the drive control module.
16.9 Remove the three M16 retaining bolts (Fig 4) securing the fan baffle to the fan assembly,
then remove the four M16 retaining bolts securing the fan baffle to the rear of the ESC cabinet. Then
remove the fan baffle, and replace the three M16 retaining bolts removed from the fan assembly.
Fig 4 Fan Baffle

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16.10 Remove the retaining bolt (Fig 5) securing the drive module to the Drive Mounting Tray.
Drive Module
Retaining bolt
Fig 5 Drive module
16.11 Disconnect the earth cable from the bottom rear of the drive module.
16.12 Remove the four M6 Allen key head bolts securing the drive module to the back panel.
WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE DRIVE MODULE IS 100 KG.
16.13 Ensure a suitable support device (not supplied) is securely positioned underneath the Drive
Module.
16.14 Carefully pull the drive module forward away from the ESC onto the support device.
Withdraw the Module until four lifting eyes are in a position to attach suitable lifting equipment.
NOTE
Ensure that the drive is supported at the sides to prevent toppling off the support device. A
minimum of two people is required for the drive removal operation.
16.15 Attach the lifting equipment to the four lifting eyes on the top of the drive module and
carefully remove the drive module from the ESC.

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17 To refit the Drive Module proceed as follows:
NOTE
The replacement Drive Module is supplied complete with the Control Module and associated option
boards (pre-fitted). Only the Drive Module is required for refitting, disconnect the Control Module
from the Drive Module and return the Control Module to store.
WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE DRIVE MODULE IS 100 KG.
17.1 Using a suitable lifting device lift the drive module to the mounting position in the ESC
17.2 Carefully slide the drive module backwards into the ESC.
17.3 Secure the drive module to the back panel using the four M6 Allen key head bolts.
17.4 Reconnect the earth cable to the bottom rear of the drive module.
17.5 Reconnect the retaining bolt (Fig 5) securing the drive module to the drive retaining tray.
17.6 Reconnect the fibre optic cables pu1 and pu2 to the drive control module.
17.7 Refit the output power cables to the busbars at the bottom of the drive module.
17.8 Reconnect the input power cables to terminals B+ and B- at the top of the drive module.
17.9 Close the two front doors and using an 8 mm Allen key secure the two quarter turn fasteners
(Fig 3). Using the key, lock the two front doors.
17.10 Refit the “weather strip” (see Fig 3).

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Control Module
18 Tools required:
(1) Allen Key: 8 mm
(2) Flat bladed Screwdriver
(3) Phillips Screwdriver
19 To remove the Control Module proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
14 fixings.
19.5 Using an 8mm Allen key release the two quarter turn fasteners (Fig 3) securing the right
19.6 Rotate the catch (Fig 6) securing the control module connection cover and remove the
connection cover from the control module.

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Upper Cover
Control Module
Catch
Connection Cover
Fig 6 Control Module – 1
19.7 Rotate the two catches (Fig 7) securing the control module upper cover. Lift up the hinged
upper cover to access the control module option boards (Fig 8).

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Catches
Cable Clamps
19.8 Remove the screws securing the cable clamps (Fig 7) at the base of the control module.
19.9 Remove the four retaining screws (Fig 8) securing the control module mounting plate to the
cabinet.

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Retaining Upper Cover

Screws
(4 off)
Mounting
Plate
Option Boards
19.10 Remove the control module and mounting plate from the cabinet.
19.11 Disconnect the connectors (Fig 9) from the rear of the control module noting the connection
details for subsequent reconnection.
Connectors
20 To refit the Control Module proceed as follows:

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NOTE
The replacement Drive Module is supplied complete with the Control Module and associated option
boards (pre-fitted). Only the Control Module is required for refitting, disconnect the Control Module
from the Drive module and return the Drive Module to store.
20.1 Reconnect the connectors to the rear of the control module as noted in Para 19.11 and as
shown in Fig 9.
20.2 Refit the control module and mounting plate to the cabinet and secure using the four
retaining screws.
20.3 The replacement Control Module is fitted with the correct five option boards (Fig 8) for this
application. Ensure the X1, X2, X3 and X6 jumpers on the Opt-A8 option board fitted in Slot A are
set as shown in Fig 10.
Jumper Block X1: Jumper Block X2: Jumper Block X6:
AI1 Mode AI2 Mode A01 Mode
A B C D A B C D A B C D
AI1 mode: 0...20mA; AI2 mode: 0...20mA; A02 mode: 0...20mA;

Current Input Current Input Current Output
A B C D A B C D A B C D
X1 X2 X6
X3
Jumper Block X3:

CMA and CMB Grounding
CMB connected from GND
CMA connected from GND
Fig 10 Option Board A8 – Jumper Settings
20.4 Secure the cable clamps (Fig 7) at the base of the control module using the screws.
20.5 Lower the hinged upper cover to cover the control module option boards.
20.6 Rotate the two catches (Fig 7) to secure the control module upper cover.
20.7 Refit the connection cover to the control module and secure by rotating the catch (Fig 6).
20.8 Close the two front doors and using an 8mm Allen key secure the two quarter turn fasteners
(Fig 3).

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Cubicle Cooling Fan
21 Tools required:
(1) Allen Key: 8mm
(2) Spanner: 24mm
(3) Terminal Screwdriver
(4) Flat Bladed Screwdriver
22 To remove the Cubicle Cooling Fan proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
14 fixings.
22.6 Disconnect the wiring from the fan terminal block (Fig 12), noting connection details for
subsequent reconnection.
22.7 Remove the three M16 retaining bolts (Fig INSERT FIG) securing the fan baffle to the fan
assembly, then remove the four M16 retaining bolts securing the fan baffle to the rear of the ESC
cabinet. Then remove the fan baffle.
22.8 Remove the remaining six M16 retaining bolts (Fig 11) securing the fan assembly to the ESC
cabinet. Also remove the two M16 retaining bolts on the sides of the fan assembly.

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Fan Fan assembly
M16 Retaining screws (9 off)
Fig 11 Fan Assembly
22.9 Carefully remove the fan assembly from the ESC.
Fan Terminal
Block
Fig 12 Fan Terminal Block

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22.10 Support the fan and remove the four M4 retaining screws (Fig 13) securing the fan to the top
of the ESC.
M4 Retaining
screws (4 off)
Fig 13 ESC – Fan Fixings
22.11 Remove the fan from the Fan Assembly.
23 To refit a Cubicle Cooling Fan proceed as follows:
23.1 The replacement fan is supplied without crimps fitted to the wiring.
23.2 Terminate each wire with the correct crimp.
23.3 Fit the fan to the fan assembly and secure using the four M4 retaining screws.
23.4 Refit the fan assembly to the ESC cabinet and secure using the nine M16 retaining bolts.
The two M16 retaining bolts at the side of the fan assembly do not need to be reattached. Make the
the two M16 retaining bolts finger tight if they are reattached.
23.5 Reconnect the wiring to the fan terminal block as noted in Para 22.6.

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Drive Module Cooling Fan
24 Tools required:
(1) Allen Key: 8mm
(2) Spanner: 13mm
(4) Wire Cutters
25 To remove the Drive Module Cooling Fan proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
14 fixings.
25.6 Remove the M8 Hex socket head bolt securing the drive module mounting tray to the cabinet
(Fig 14).

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Drive Module Cooling Fan
M8 Hex Socket Head Bolt
Drive Module Mounting Tray
Fig 14 Drive Module Cooling Fan – 1
25.7 Remove the two M5 screws securing the connection cover to the drive module (Fig 15).
Remove the connection cover.
Connection
Cover
M5 Screws
(2 off)
Drive Module
Cooling Fan
25.8 Disconnect the fan supply cable connector (Fig 16).

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Fan Supply
Cable Connector
Drive Module
Cooling Fan
25.9 Remove the M3 screw securing the cable clip to the drive module cooling fan assembly
(Fig 17).
M5 Screws
(4 off)
25.10 Remove the four M5 screws securing the cooling fan to the Drive Module.
25.11 Pull the cooling fan out of the cabinet.

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25.12 Cut the cable tie securing the fan supply cable to the fan assembly (Fig 18).
Fan Supply
Cable
Cable Tie
Grommet
25.13 Pull the fan supply cable through the rubber grommet in the fan assembly.
25.14 Remove the four M4 screws securing the fan support to the fan assembly and remove the
fan support (Fig 19).
M4 Screws
(4 off)
Fan Support

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25.15 Remove the three M4 screws securing the intake cone to the fan assembly and remove the
intake cone (Fig 20).
M4 Screws
(3 off)
Intake Cone
25.16 Remove the four M4 screws securing the cooling fan to the fan support and remove the
cooling fan (Fig 21).
M4 Screws
(4 off)
Cooling Fan Support

Fan

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26 To refit a drive module cooling fan proceed as follows:
26.1 Fit the cooling fan to the fan support and secure using the four M4 screws (Fig 21).
26.2 Fit the intake cone to the fan assembly and secure using the three M4 screws (Fig 20).
26.3 Fit the fan support to the fan assembly and secure using the four M4 screws (Fig 19).
26.4 Feed the fan supply cable through the rubber grommet in the fan assembly (Fig 18).
26.5 Secure the fan supply cable to the fan assembly using the cable tie (Fig 18).
26.6 Slide the cooling fan into the cabinet and secure using the four M5 screws (Fig 17).
26.7 Refit the cable clip to the drive module cooling fan assembly and secure using the M3 screw
(Fig 17).
26.8 Reconnect the fan supply cable connector (Fig 16).
26.9 Refit the connection cover to the drive module and secure using the two M5 screws (Fig 15).
26.10 Secure the drive module mounting tray to the cabinet using the M8 Hex socket head bolt
(Fig 14).

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Soft Start Contactor
27 Tools required:
(1) Allen Key: 8mm
28 To remove the Soft Start Contactor (CTR3) proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
14 fixings.
28.6 Disconnect the wiring from the CTR3 terminals, noting connection details for subsequent
reconnection.

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Wiring
Terminals
CTR3
Mounting
Rail
Wiring
Terminals
Fig 22 Soft Start Contactor (CTR3)
28.7 Unclip CTR3 from the mounting rail.
29 To refit the Soft Start Contactor (CTR3) proceed as follows:
29.1 Clip CTR3 to the mounting rail.
29.2 Reconnect the wiring to CTR3 as noted in Para 28.6.

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Fan Filter
30 Tools required:
31 To remove the Fan Filter at the bottom of the ESC proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING
LETHAL VOLTAGE. WAIT FIVE MINUTES BEFORE REMOVING ELECTRIC START

CONTROLLER AIR VENTS
31.3 Wait for five minutes.
31.4 Release the ten captive screws (Fig 23) securing the air vent at the bottom of the ESC.
Captive Screws (10 off) Air Vent
Fig 23 ESC bottom air vent

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31.5 Remove the air vent from the bottom of the ESC
31.6 Remove the fan filter from behind the air vent.
31.7 Release the twelve captive screws (Fig 24) securing the air vent at the top of the ESC
cubicle.
Captive Screws (12 off) Air vent
Fig 24 ESC top air vent
31.8 Remove the air vent from the top of the ESC cubicle.
31.9 Remove the fan filter from behind the air vent.
31.10 Release the twelve captive screws (Fig 25) securing the air vent on the left hand side ESC
cubicle door.
Air vent
Captive Screws (12 off)
Fig 25 ESC top air vent
32 To refit the Fan Filter proceed as follows:
32.1 Refit the fan filter to the rear of the top air vent.
32.2 Refit the air vent at the top of the ESC cubicle and secure using the twelve captive screws.

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32.3 Refit the fan filter to the rear of the bottom air vent.
32.4 Refit the air vent at the bottom of the ESC and secure using the ten captive screws.
32.5 Switch on the 380-690V 50/60 Hz three-phase mains supply to the ESC at the external
isolator.
32.6 Switch on the 110V/230V 60Hz single-phase ACH supply to the ESC at the external isolator.

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Fuses
33 Tools required:
(1) Allen Key: 8mm
34 To replace fuses FS7 to FS11 and FS18 to FS20 in the ESC proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
14 fixings.
34.6 Fuses FS7 to FS9 are shown in Fig 26, fuses FS10 to FS11 are shown in Fig 27, fuse FS18
is shown in Fig 28 and fuses FS19 to FS20 are shown in Fig 29.

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FS7 FS8 FS9
Fig 26 ESC Fuses FS7 to FS9
FS10
FS11

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FS18
Fig 28 ESC Fuse FS18
FS19
FS20
34.7 Pull down the fuse holder to gain access to the fuse as shown in Fig 30.

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Fuse
Fuse
Holder
Fig 30 ESC Fuses FS7 to FS11 and FS18-20 – Fuseholder
34.8 Remove the fuse from the fuse holder.
34.9 Fit a replacement fuse and close the fuse holder.
35 To replace fuses FS1 to FS6 and FS12 to FS17 in the ESC proceed as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.

UNCLASSIFIED
14 fixings.
35.6 Remove the M8 bolts securing the fuses to the fuse board.
35.7 Remove fuse from bus bars.
35.8 Fit a replacement fuse and secure with the M8 bolts and washers.
Fuse
M8 bolt
Fig 31 ESC Output fuses FS12 to FS17

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Fig 32 ESC Input fuses FS1 to FS6

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Junction Box
36 Tools required:
(1) Spanner: 10mm, 19mm
37 The Junction Box is an LRU, to remove the Junction Box proceed as follows:
and lock out.
37.2 Remove the six M6 retaining bolts securing the cover to the front of the Junction Box.
37.3 Remove the cover from the Junction Box.
37.4 Disconnect the cable cores from the terminal blocks mounted inside the Junction Box, noting
connection details for subsequent reconnection.
37.5 Remove the cables from the Junction Box cable glands.
37.6 Disconnect the Earth Strap from the Junction Box M10 earth stud.
WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE JUNCTION BOX IS 36KG.
37.7 Remove the four M10 retaining bolts securing the Junction Box to the installation site.
37.8 Remove the Junction Box from the installation site.
38 To refit a Junction Box proceed as follows:
38.1 Remove the four M6 retaining bolts securing the cover to the front of the Junction Box.
38.2 Remove the cover from the Junction Box.
38.3 Drill the Junction Box gland plates with suitable holes for the cable glands.
38.4 Fit the cable glands to the Junction Box gland plates.
WARNING
EXCESSIVE WEIGHT. THE WEIGHT OF THE JUNCTION BOX IS 36KG.
38.5 Offer the Junction Box to the installation site and secure using the four M10 retaining bolts.
38.6 Connect the Earth Strap to the Junction Box M10 earth stud.
38.7 Feed the cables through the cable glands on the Junction Box gland plates.
38.8 Terminate the cable cores to the terminal blocks mounted inside the Junction Box as noted
in Para 37.4.
38.9 Refit the cover to the front of the Junction Box and secure using the six M6 retaining bolts.

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PREVENTIVE MAINTENANCE
39 The preventive maintenance procedures for the ESS are detailed in Paras 41 to 53.4 and should be
carried out on the ESS unless otherwise stated, at the time intervals specified.
40 As the electronics are almost entirely solid state, electrical maintenance procedures are kept to a
minimum. Hence, most of the following checks relate to the mechanical aspects of the equipment.
ESM
Oil Connection Inspection
41 Inspect oil supply and return connections at Electric Start Motor for integrity (leaks) as follows:
WARNINGS
(1) EXCESSIVE HEAT. THE SURFACES OF THE ESM MAY BE HOT. ALLOW FOUR
MINUTES OF NON-OPERATION BEFORE TOUCHING ESM.
(2) EXCESSIVE HEAT. THE SURFACES OF THE OIL SUPPLY PIPING MAY BE HOT.
ALLOW FOUR MINUTES OF NON-OPERATION BEFORE TOUCHING OIL SUPPLY PIPING.

EMPLOYED.
and lock out.
41.2 Check the ESM oil supply and return for any obvious signs of leakage.
Oil Supply Inlet Oil Supply Outlet
Fig 33 Oil connections - ESM
41.3 Report and rectify any deficiencies.
41.4 Switch on the 380-690V 50/60 Hz three-phase mains supply to the ESC at the external
isolator.

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Earth Bonding Continuity
42 Tools required:
(1) Continuity Tester.
43 Inspect and Measure earth bonding continuity on the Electric Start Motor.
WARNINGS

EMPLOYED.
and lock out.
and lock out.
44 Visually inspect the earthing arrangements for damage or corrosion at both the Electric Start Motor
and external structure ends. If either shows signs of damage or corrosion carry out remedial actions in
accordance with the procedure outlined below.
44.1 Ensure that all earthing arrangement fixing nuts/bolts are tight.
WARNING
EARTH CONNECTION. UNDER NO CIRCUMSTANCES SHOULD THE EARTH
ARRANGEMENTS OR THE EQUIPMENT BE DISCONNECTED FROM EARTH BEFORE
ALL POWER SUPPLIES ARE ISOLATED AT SOURCE. TAG OUT SYSTEM SHOULD BE
EMPLOYED.
44.2 Remove corrosion as follows:
44.2.1 Disconnect the earthing arrangement from station’s earth point and equipment.
44.2.2 Remove all traces of paint, grease, scale and rust from studs, nuts, bolts, washers
and straps. All surfaces are to show bright metal. Replace the strap, if damaged, with new
serviceable item.
44.2.3 Reconnect earthing arrangement to station’s earth point and equipment.
44.3 Perform an electrical check as follows:
44.3.1 Connect a continuity tester on its 10A range between the main earth stud on the
top of the cabinet and the earth point on the station’s structure.
44.3.2 Measure the earth bonding resistance and ensure the resistance is less than
0.05Ω.

UNCLASSIFIED
ESC
Earth Bonding Continuity
45 Tools required:
(1) Continuity Tester.
46 Inspect and Measure earth bonding continuity on the Electric Start Controller as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
47 Visually inspect the earthing arrangements for damage or corrosion at both the Electric Start
Controller and external structure ends. If either shows signs of damage or corrosion carry out remedial
actions in accordance with the procedure outlined below.
47.1 Ensure that all earthing arrangement fixing nuts/bolts are tight.
WARNING
EARTH CONNECTION. UNDER NO CIRCUMSTANCES SHOULD THE EARTH
ARRANGEMENTS OR THE EQUIPMENT BE DISCONNECTED FROM EARTH BEFORE
ALL POWER SUPPLIES ARE ISOLATED AT SOURCE. TAG OUT SYSTEM SHOULD BE
EMPLOYED.
47.2 Remove corrosion as follows:
47.2.1 Disconnect the earthing arrangement from station’s earth point and equipment.
47.2.2 Remove all traces of paint, grease, scale and rust from studs, nuts, bolts, washers
and straps. All surfaces are to show bright metal. Replace the strap, if damaged, with new
serviceable item.
47.2.3 Reconnect earthing arrangement to station’s earth point and equipment.
47.3 Perform an electrical check as follows:
47.3.1 Connect a continuity tester on its 10A range between the main earth stud on the
top of the cabinet and the earth point on the station’s structure.
47.3.2 Measure the earth bonding resistance and ensure the resistance is less than
0.05Ω.

UNCLASSIFIED
Air Cooling Filter Element Renewal
48 Tools required:
49 Renew the air cooling filter elements on the ESC as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING
LETHAL VOLTAGE. WAIT FIVE MINUTES BEFORE REMOVING ELECTRIC START

CONTROLLER AIR VENTS
49.3 Wait for five minutes
49.4 Follow the procedures detailed in Chapter 5 pages 35 to 37 for the Air Filter replacement.

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Drive Module Cooling Fan Renewal
50 Tools required:
(1) Allen Key: 8mm
(2) Spanner: 13mm
(4) Wire Cutters
51 Renew the drive module cooling fans in the ESC as follows:
WARNINGS

EMPLOYED.
51.1 Isolate the 380-690 V 50/60 Hz three-phase mains supply to the ESC at the external isolator
and lock out.
51.2 Isolate the 110 V/230 V 60 Hz single-phase ACH supply to the ESC at the external isolator
and lock out.
WARNING

CONTROLLER DOORS
been removed.
51.4 Follow the procedures detailed in Chapter 5 pages 27 to 32 for the Drive Module Cooling
Fan replacement

UNCLASSIFIED
Cubicle Cooling Fan Renewal
52 Tools required:
(1) Allen Key: 8mm
(4) Spanner: 24mm
53 Renew the air cooling fans in the ESC as follows:
WARNINGS

EMPLOYED.
and lock out.
and lock out.
WARNING

CONTROLLER DOORS
been removed.
53.4 Follow the procedures detailed in Chapter 5 pages 24 to 26 for the Cubicle Cooling Fan
replacement.

UNCLASSIFIED
IN STORAGE MAINTENANCE
Bar Over Motor
54 Tolls required:
(1) Bar over tool.
55 Manually bar over Electric Start Motor in storage as follows:
55.1 Remove appropriate packaging from the ESM as applicable.
55.2 Ensure there is adequate space around the ESM to perform the preventive maintenance
task.
55.3 Fit the bar over tool to the end of the rotor shaft.
55.4 Rotate the bar over tool 360° twice and then rotate a further 180° (this ensures the rotor is
not left in the position it started).
55.5 Remove the bar over tool from the end of the rotor shaft.
55.6 Replace the packaging removed in Para 55.1.
Capacitor Charging
56 Tools required:
(1) DC Power Supply with adjustable current limit
57 To charge the Drive Module capacitors when in storage proceed as follows:
57.1 Remove appropriate packaging from the Drive Module as applicable.
57.2 Ensure there is adequate space around the Drive Module to perform the preventive
maintenance task.
WARNING
LETHAL VOLTAGE. SUPPLY VOLTAGES USED IN THIS EQUIPMENT ARE

ISOLATORS BEFORE CARRYING OUT REMEDIAL ACTION. TAG OUT SYSTEM
SHOULD BE EMPLOYED.
57.3 Ensure the DC Power Supply is switched off.

UNCLASSIFIED
57.4 Connect the output of the DC power supply to the B+/B- terminals on the top of the Drive
Module (refer to Fig 34).
Fig 34 Drive Module DC Power Supply Connections
57.5 Ensure the DC output voltage of the DC Power Supply is set to zero.
WARNING
LETHAL VOLTAGE. SUPPLY VOLTAGES USED IN THIS EQUIPMENT ARE

ISOLATORS BEFORE CARRYING OUT REMEDIAL ACTION. TAG OUT SYSTEM
SHOULD BE EMPLOYED.
57.6 Switch on the DC Power Supply.
57.7 Set the current limit on the DC Power Supply to 500mA.
57.8 Gradually increase the DC output voltage of the DC Power Supply to 700V.
57.9 Continue to apply the DC voltage to the Drive Module for a period of one hour.
57.10 After one hour decrease the DC output voltage of the DC Power Supply to zero.
57.11 Switch off the DC Power Supply.
57.12 Disconnect the DC Power Supply from the Drive Module.
57.13 Repack the Drive Module using the original packaging.

UNCLASSIFIED
CHAPTER 6
MAINTENANCE SCHEDULES
CONTENTS
Page
Introduction 1
TABLES
Page
Table 1 Preventive Maintenance Periodicity 1
Table 2 Instore Maintenance Periodicity 2
INTRODUCTION
1 Table 1 lists the periodicity of the preventive maintenance procedures:
H Hours of operation
D Day
W Week
M Month
Y Year
TABLE 1 PREVENTIVE MAINTENANCE PERIODICITY
PROCEDURE PERIODICITY PROCEDURES

Inspect oil supply and return connections at Electric Start Motor D Chapter 5
for integrity (leaks) Para 41
Manually bar over Electric Start Motor in storage 3M Chapter 5
Para 54
Charge Drive Module Capacitors when in storage/return to OEM Y Chapter 5
Para 42
Inspect and Measure earth bonding continuity on the Electric 18 M Chapter 5
Start Controller, Cable Junction Box and Electric Start Motor Para 56
Renew Electric Start Controller cubicle air cooling filter element 2Y Chapter 5
Para 45
Renew Electric Start Controller Drive module cooling fans 5Y Chapter 5
Para 0
Renew Electric Start Controller air cooling fans 5Y Chapter 5
Para 50

UNCLASSIFIED
TABLE 2 INSTORE MAINTENANCE PERIODICITY
PROCEDURE PERIODICITY PROCEDURES

Manually bar over Electric Start Motor in storage 3M Chapter 5
Para 54
Charge Drive Module Capacitors when in storage/return to OEM Y Chapter 5
Para 42

UNCLASSIFIED
CHAPTER 7
PARTS CATALOGUE
CONTENTS
Page
Introduction 1
TABLES
Page
Table 1 Electric start system 1
INTRODUCTION
1 This Parts Catalogue is designed as an aid to the identification of component parts or assemblies of
parts of the equipment, and to provide the information necessary for the demanding of spares.
TABLE 1 ELECTRIC START SYSTEM
Description Part No. Quantity

Electric Start Motor E00000063 1
Electric Start Controller E00000064 1
Drive Module 28934C63790C DR12649 1
Control Module 28934C63790C DR12649 1
Cubicle Cooling Fan 22375A64025C 2
Drive Module Cooling Fan PP01080 2
Soft Start Contactor 25762A64040C 1
Fan Filter E00002659 1
Fuse, 200A (FS1-6) 100437 6
Fuse, 4A (FS7-9, 18, 20) 100048 5
Fuse, 10A (FS10-11) 100850 2
Fuse, 2A (FS19) 100460 1
Fuse, 250A (FS12-17) 100432 6
Junction Box E00000067 1
Cable Assembly 2 E00000066 1
Motor Installation Kit E00002703 1
Cable Cowl Assembly E00003262 1
Plain Washer M6 21171A1004 6
Screw M6 x 20 Hex Head 21841A49803 6
Copper Tube Crimp Lug 100757 2

UNCLASSIFIED
Description Part No. Quantity

Nut M10 Full Hex 21883A40109 2
Earth Cable E00002009 1
Plain Washer M10 100220 3
Spring Washer M10 21171A1005 2
2
Copper Tube Crimp Lug 70mm 25233A63967 6
2
Copper Tube Crimp Lug 16mm 25233A63966 8
Nut M12 Custom E00000127 12
Tab Washer E00003572 12
Star Link E00003582 1
Delta Link E00003592 3
Angle Position Washer - Terminal E00002756 3
Angle Position Washer – Ground E00002755 3
Terminal Assembly Aid E00002759 1


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UNCLASSIFIED

Ultra Electronics, PMES

Doc No. 1003795

First used on Contract: W2189

Written by: GFOSTER

Date: 20 Apr 2010

Doc No. 1003795 Commercial In Confidence

R STATUS DATE APPROVAL COMMENTS

POSITION NAME POSITION NAME

Author G Foster Project Manager A Tunstall

Electronic (will be notified on change)

POSITION NAME POSITION NAME

Commercial In Confidence Doc No. 1003795

Doc No. 1003795 Commercial In Confidence

Front cover (title page) ................................................................................................................................ i

Chapter 1 Purpose and Planning Information

Commercial In Confidence Doc No. 1003795

ACH Anti Condensation Heater

Doc No. 1003795 Commercial In Confidence

DeviceNet DeviceNet is a communication protocol used in the automation industry to interconnect

Commercial In Confidence Doc No. 1003795

PUBLICATION TITLE REF No.

Doc No. 1003795 Commercial In Confidence

(6) EXCESSIVE WEIGHT. THE WEIGHT OF THE ELECTRIC START CONTROLLER IS

(8) EXCESSIVE WEIGHT. THE WEIGHT OF THE JUNCTION BOX IS 36 KG.

(10) LETHAL VOLTAGE. THE EQUIPMENT EARTH STRAPS MUST BE SECURELY

(11) LETHAL VOLTAGE. SUPPLY VOLTAGES USED IN THIS EQUIPMENT ARE

Commercial In Confidence Doc No. 1003795

(16) EARTH CONNECTION. UNDER NO CIRCUMSTANCES SHOULD THE EARTH

(18) ENCLOSURE RATING. THE CONTROLLER IP52 ENCLOSURE RATING IS ONLY

Doc No. 1003795 Commercial In Confidence

(4) EQUIPMENT DAMAGE. Ensure there is a minimum clearance of 13 mm between

Commercial In Confidence Doc No. 1003795

Doc No. 1003795 Commercial In Confidence

(1) ATEX Directive 94/9/EC.

3 The ESM is marked as follows:

CERTIFICATION NOT YET

CERTIFICATION NOT YET

ELECTRIC START CONTROLLER

(1) EMC Directive 2004/108/EC

(2) Low Voltage Directive 73/23/EEC

(3) Machinery Directive 2006/42/CE

6 The ESC is marked as follows:

CERTIFICATION NOT YET

Commercial In Confidence Doc No. 1003795

(1) ATEX Directive 94/9/EC.

10 The Junction Box is marked as follows:

12 The following standards are applicable to / referenced on cable drawing 700017016_02

(1) UL758 – Appliance Wiring Material incorporating:

a. Style 2750 – Shielded and Jacketed Cable

b. Style 1330 – Insulated Wire

(2) Low Voltage Directive 73/23/EEC – Cable is according to CE

Doc No. 1003795 Commercial In Confidence

PURPOSE AND PLANNING INFORMATION

Doc No. 1003795 Commercial In Confidence