Work Instructions: Capstone C200/C1000 Series Microturbine
Work Instructions: Capstone C200/C1000 Series Microturbine
Work Instructions: Capstone C200/C1000 Series Microturbine
Table of Contents
1. Introduction ........................................................................................................................... 5
1.1. Purpose and Scope ..................................................................................................... 5
1.2. Capstone Document Links ........................................................................................... 5
1.3. Safety Procedures ....................................................................................................... 6
1.4. Safety Symbols ............................................................................................................ 7
2. Maintenance During Storage ................................................................................................. 8
2.1. Basic Storage Requirements (up to 6 Months) ............................................................. 8
2.2. Extended Storage Requirements (6 Months or longer)................................................. 8
2.3. Battery Maintenance (If Equipped) ............................................................................... 8
2.3.1. Sleep Mode ..................................................................................................... 9
2.3.2. Automatic Battery Charge ............................................................................. 10
2.3.3. Equalization Charge ...................................................................................... 10
3. General Maintenance Procedures ....................................................................................... 11
3.1. General Cleaning and Inspection ............................................................................... 11
3.2. Site Air Quality, Air Filter and Internal Component Maintenance ................................ 11
3.2.1. Site-Specific Air Filter Replacement Interval Evaluation ................................ 12
4. Fuel System Inspection and Maintenance ........................................................................... 13
4.1. Gaseous Fuel Fittings and Components .................................................................... 13
4.2. Liquid Fuel Fittings and Components ......................................................................... 14
5. Scheduled Maintenance Tables .......................................................................................... 14
5.1. Capstone System Scheduled Maintenance Tables .................................................... 14
5.2. Controllers and Accessories Scheduled Maintenance ................................................ 27
6. Responsibility ...................................................................................................................... 28
7. Capstone Technical Support ............................................................................................... 28
7.1. Capstone Document Library....................................................................................... 28
List of Tables
Table 1. C200/C1000 HPNG & Propane (Fuel Types H, P) Schedule – 4K to 80K Hours ........ 15
Table 2. C200/C1000 HPNG & Propane (Fuel Types H, P) Schedule – 84K to 160K Hours .... 16
Table 3. C200/C1000 LPNG (Fuel Type F) Schedule – 4K to 80K Hours ................................. 17
Table 4. C200/C1000 LPNG (Fuel Type F) Schedule – 84K to 160K Hours ............................. 18
Table 5. C200/C1000 Biogas (Fuel Types A, B) Schedule – 4K to 80K Hours ......................... 19
Table 6. C200/C1000 Biogas (Fuel Types A, B) Schedule – 84K to 160K Hours ..................... 20
Table 7. C200/C1000 HP Sour Gas (Fuel Type S) Schedule – 4K to 80K Hours ..................... 21
Table 8. C200/C1000 HP Sour Gas (Fuel Type S) Schedule – 84K to 160K Hours ................. 22
Table 9. C200/C1000 Liquid Fuel (Fuel Type D) Schedule – 4K to 80K Hours ......................... 23
Table 10. C200/C1000 Liquid Fuel (Fuel Type D) Schedule – 84K to 160K Hours ................... 24
Table 11. Additional C200/C1000 HazLoc Tasks Schedule – 4K to 80K Hours ......................... 25
Table 12. Additional C200/C1000 HazLoc Tasks Schedule – 84K to 160K Hours ..................... 26
Table 13. Capstone Controllers Scheduled .............................................................................. 27
1. Introduction
1.1. Purpose and Scope
This document lists standard maintenance intervals for Capstone C200 and C1000 Series
MicroTurbine® systems and major accessories.
All maintenance procedures must be performed by an Authorized Service Provider (ASP).
NOTE
Refer to specific Work Instructions to replace components or to complete the
maintenance listed. Many procedures are linked to Work Instructions or other
documents.
Disconnect system from the utility. Isolate and lock out the utility (if applicable).
Isolate and lock out any other sources of power to the microturbine. For example,
connections to the solid state relays in the microturbine Communications Bay.
If battery pack is installed, set and lock battery pack circuit breaker OFF, and
disconnect/unplug battery cables.
Ensure above power sources are OFF and the system has been disconnected for at least
10 minutes to reduce electric shock hazards.
Maintain proper microturbine frame electrical ground.
For Hazardous Locations (HazLoc) Package applications (e.g., ATEX or CID2), the
pressurized enclosure shall not be opened unless:
● the system is not in operation;
● the surrounding/adjacent area is known to be free of flammable materials;
● the local atmosphere is not explosive;
● the microturbine indicated internal temperature is below 450°C (842°F);
● all devices have been isolated and de-energized for five minutes.
Warning labels similar to the following are attached to systems in these applications.
HIGH VOLTAGE WARNING: Identifies a high voltage hazard that can result in
personal injury or death.
HOT SURFACE/AREA WARNING: Identifies a hot surface or area that can result
in personal injury.
ACOUSTIC EMISSIONS WARNING: Identifies sound level hazard that can result
in personal injury. Hearing protection is required.
extended system down time or during storage, battery packs will self-discharge and require
periodic recharging (440073).
If possible, do not store battery-equipped systems or battery packs at temperatures above 40°C
(104°F). Battery life may be shortened during long-term storage above this temperature.
Fully charge the battery pack before placing system into storage, at recharge intervals shown in
the table and again when the system is put into or returned to service.
If battery-equipped systems will be stored for 6 months or longer, recharge the battery pack as
shown in the following table. Charging the battery pack during storage will reduce the possibility
of shortened battery life during storage up to one year. Battery life may be reduced during storage
times longer than one year even with proper battery maintenance.
Recharge intervals for battery packs in storage with the battery circuit breaker/isolation switch
OFF depend on ambient storage temperatures. Do not exceed the battery pack recharge intervals
shown in the following table. Recharge intervals also apply to UCB/JUCB batteries stored
unplugged from UCB/JUCB.
The battery circuit breaker acts as an isolation switch to allow battery disconnection for system
service or for long-term system storage. Set battery circuit breaker to OFF under any of the
following conditions:
● while performing microturbine maintenance/service tasks;
● when transporting the microturbine;
● if microturbine will not be operated for a period longer than 14 days.
NOTE
Recharge intervals in the following table do not apply to UCB/JUCB batteries.
NOTE
If the system will be in Stand Alone Sleep Mode for more than 5 to 7 days,
disconnect modem (if installed) to avoid UCB/JUCB battery discharge.
flow. Engine intake air and enclosure air filters require periodic cleaning or replacement as shown
in the maintenance tables.
Particles will cling to surfaces inside the system enclosure. When mixed with naturally occurring
moisture, this particle buildup may form restrictions to air flow over heatsinks and other
components that rely on cooling air flow. Overheating can occur, and lead to reduced performance
and/or system shutdown or failure. Other electronic and mechanical devices can be adversely
affected by poor air quality. Corrosion, caked-on dirt or discolored component surfaces may be
signs of adverse air quality.
2. Use site profile information to supplement air filter inspection and replacement intervals
listed in scheduled maintenance tables.
3. Also monitor system for “9043” fault declarations, which may indicate that IGBT heat
sinks are overheating due to contaminant buildup and require cleaning.
ELECTRICAL WARNING
ELECTRICAL HAZARD! Use extreme caution and wear appropriate PPE
(Personal Protective Equipment) when working on energized equipment. Failure
to obey this warning may result in personal injury or death.
a. Start engine.
b. With engine running at idle, use leak detector to check fuel tubes and fittings, fuel
regulator (if installed), fuel filter and manifold connections for leaks. If using a liquid
leak solution, absorb excess liquid with shop towels to ensure no liquid drops onto
the electronic controllers.
c. If a gaseous fuel leak is found, stop the system immediately. Close the main fuel
supply valve. Repair the leak. Tighten fittings to specified torque (440072). Capstone
kit 610125-1XX contains Loctite® #567 and instructions for use with NPT fittings
(440147).
d. If a compression fitting cannot be sealed, do not tighten past specified torque
(440072). Order and install a replacement tube and fitting.
4. After tightening or replacing a fitting, open fuel supply inlet valve, start engine, and
confirm that leak has been repaired.
NOTE
When compressor is operating at 0 kW demanded load, compressor bottom sight
glass must be ½-full and top sight glass must be empty.
5. For LPNG microturbines: Check oil levels in primary oil separator, and add or remove
oil as needed. See note above regarding turbine operation and required oil levels.
6. If a gaseous fuel leak persists, contact Capstone Technical Support.
WARNING
FUEL EXPOSURE HAZARD! Wear appropriate personal protective equipment
including fuel-resistant gloves and eye protection when handling fuel system
components. Exposure to liquid fuel may cause skin and eye irritation or injury.
Inspect the entire fuel system for leaks according to the maintenance schedule and whenever a
fuel system component is loosened, disconnected or replaced. Leak check fuel filter housing after
fuel filter inspection.
1. Inspect all fittings, connections, filters, fuel pumps, and valves from the fuel supply inlet
into the microturbine for fuel build-up and/or leaks. Tighten fittings, repair leaks, and/or
replace leaking or damaged components.
2. Check for excessive fuel build-up on surfaces of components and assemblies where fuel
may drip and accumulate. Evidence of fuel leakage may include small liquid puddles or
oily dirt smudges. Tighten fittings and/or replace leaking or damaged components.
3. If a liquid fuel leak persists, contact Capstone Technical Support.
4. Check oil level in air assist compressor.
a. If system is operating, compressor sight-glass should be 1/2 covered by oil. If level is
lower, add oil.
b. If system is not operating, check oil as follows:
i. Make sure compressor vent cycle is complete.
ii. Open test valve to vent pressure from the aftercooler and pipework.
iii. Make sure that compressor pressure gauge indicates 0 psi.
iv. Oil should completely cover sight-glass. If level is lower, add oil.
Table 1. C200/C1000 High Pressure Natural Gas and Propane (Fuel Types H, P) Maintenance Schedule – 4K to 80K Hours
Work
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
Air Filtration
440342, Es ta bl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
440250,
440186
Anti -Condens a ti on Hea ters Ins pect every 12 months 1 Hi gh humi di ty s ys tems onl y.
Fuel Sys tem (Li nes a nd Fi tti ngs ) S S S S S S S S S S S S S S S S S S S S See Gaseous Fuel Fittings and Components s ecti on i n thi s document.
Hea t Tra ce Wi ri ng (Propa ne Onl y) Perform MegOhm Check every 12 months • Perform Fuel Hea der Ω i ns ul a ti on check to ens ure proper opera ti on
of a l l ci rcui t l ea ds . Nomi na l Ω rea di ng s houl d be grea ter tha n 10 MΩ.
• If MΩ check fa i l s , conta ct Ca ps tone Techni ca l Support.
Injector As s embl i es 440193 I I R I I R I I R I I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 2. C200/C1000 High Pressure Natural Gas and Propane (Fuel Types H, P) Maintenance Schedule – 84K to 160K Hours
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
Air Filtration
440342, Es ta bl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
440250,
440186
1
Anti -Condens a ti on Hea ters Ins pect every 12 months Hi gh humi di ty s ys tems onl y.
Fuel Sys tem (Li nes a nd Fi tti ngs ) S S S S S S S S S S S S S S S S S S S S See Gaseous Fuel Fittings and Components s ecti on i n thi s document.
Hea t Tra ce Wi ri ng (Propa ne Onl y) Perform MegOhm Check every 12 months • Perform Fuel Hea der Ω i ns ul a ti on check to ens ure proper opera ti on
of a l l ci rcui t l ea ds . Nomi na l Ω rea di ng s houl d be grea ter tha n 10 MΩ.
• If MΩ check fa i l s , conta ct Ca ps tone Techni ca l Support.
Injector As s embl i es 440193 I I R I I R I I R I I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 3. C200/C1000 Low Pressure Natural Gas (Fuel Type F) Maintenance Schedule – 4K to 80K Hours
Work
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
Air Filtration
440342, Es ta bl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
440250,
440186
Anti -Condens a ti on Hea ters Ins pect every 12 months 1 Hi gh humi di ty s ys tems onl y.
Vi s ua l l y i ns pect hea t excha nger exteri or s urfa ces for pi nhol e or wel d
Hea t Excha nger I I I I C I I I I R
joi nt l ea ks .
Pul l tes t a l l power a nd control ca bl es to check for da ma ge, broken
Fuel Gas Booster (FGBR)
Wi ri ng a nd Ca bl i ng 440203 I I I I I I I I I I s tra nds or l oos e mounts . Ens ure a ny termi na l connecti ons a re
properl y s ecured.
Va ri a bl e Frequency Dri ve (VFD) Hea t
C C C C C C C C C C
Si nk
Va ri a bl e Frequency Dri ve (VFD) Fa n Repl a ce every 3 yea rs
Second Sta ge Oi l Sepa ra tor 440201 R R R R R R R R R R
FGBR Oi l 440359 R R R R R R R R R R Dra i n a nd repl eni s h oi l .
Oi l Fi l ter 440358 R R R R R R R R R R
PLC Ba ttery Repl a ce every 3 yea rs
Scrol l Compres s ors R R
Fuel Supply, Combustion
Fuel Sys tem (Li nes a nd Fi tti ngs ) S S S S S S S S S S S S S S S S S S S S See Gaseous Fuel Fittings and Components s ecti on i n thi s document.
440066, Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y)
410072 20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
More frequent repl a cement ma y i ndi ca te s i te ha rmoni c di s torti on
EMI Fi l ter R R R R
Elect and Cables
R R
Genera tor Bl ower Hos e obs erved.
Powerhea d Shroud Ora nge Sea l I R Repl a ce i f cra cked or bri ttl e.
Si l i cone/Fi bergl a s s Exha us t Sl eeves I R Repl a ce i f da ma ged.
Exha us t Ba ckfl ow Va l ve Sys tems wi th common exha us t onl y. Repl a ce i f da ma ge or
440334 I I I I I I I I I I
(If i ns ta l l ed) deteri ora ti on i s obs erved.
Encl os ure Pa nel Acous ti c Foa m I I I R Repl a ce i f cra cked or bri ttl e.
1
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC (18ºF) a bove a mbi ent tempera ture. Legend
Hea ters a re externa l l y powered. Refer to Ca ps tone Mi croturbi ne Hi gh Humi di ty Pa cka ge Appl i ca ti on Gui de
I = Inspect R = Replace
(480035).
C = Clean S = See instructions in this document
Table 4. C200/C1000 Low Pressure Natural Gas (Fuel Type F) Maintenance Schedule – 84K to 160K Hours
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
Air Filtration
440342, Es ta bl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
440250,
440186
Anti -Condens a ti on Hea ters Ins pect every 12 months 1 Hi gh humi di ty s ys tems onl y.
Vi s ua l l y i ns pect hea t excha nger exteri or s urfa ces for pi nhol e or wel d
Hea t Excha nger I I I I C I I I I R
joi nt l ea ks .
Fuel Gas Booster (FGBR)
Fuel Sys tem (Li nes a nd Fi tti ngs ) S S S S S S S S S S S S S S S S S S S S See Gaseous Fuel Fittings and Components s ecti on i n thi s document.
440066, Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y)
410072 20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
More frequent repl a cement ma y i ndi ca te s i te ha rmoni c di s torti on
EMI Fi l ter R R R R
Elect and Cables
R R
Genera tor Bl ower Hos e obs erved.
Powerhea d Shroud Ora nge Sea l I R Repl a ce i f cra cked or bri ttl e.
Si l i cone/Fi bergl a s s Exha us t Sl eeves I R Repl a ce i f da ma ged.
Exha us t Ba ckfl ow Va l ve Sys tems wi th common exha us t onl y. Repl a ce i f da ma ge or
440334 I I I I I I I I I I
(If i ns ta l l ed) deteri ora ti on i s obs erved.
Encl os ure Pa nel Acous ti c Foa m I I I R Repl a ce i f cra cked or bri ttl e.
1
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC (18ºF) a bove a mbi ent tempera ture. Legend
Hea ters a re externa l l y powered. Refer to Ca ps tone Mi croturbi ne Hi gh Humi di ty Pa cka ge Appl i ca ti on Gui de
I = Inspect R = Replace
(480035).
C = Clean S = See instructions in this document
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
Air Filtration
440342,
440185,
Injector As s embl i es I R I R I R I R I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440250,
440186
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f da ma ge obs erved
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216 cycl e, a nd Battery Maintenance for recha rge i nterva l s .
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t)
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Electronics and Cables
Powerhea d 440316 R R
Dump Va l ve Hos e a nd Repl a ce when repl a ci ng powerhea d, a nd i f cra cki ng or bri ttl enes s i s
R R
Genera tor Bl ower Hos e obs erved.
Powerhea d Shroud Ora nge Sea l I R I R Repl a ce i f cra cked or bri ttl e.
Si l i cone/Fi bergl a s s Exha us t Sl eeves I R Repl a ce i f da ma ged.
Exha us t Ba ckfl ow Va l ve Sys tems wi th common exha us t onl y. Repl a ce i f da ma ge or
440334 I I I I I I I I I I
(If i ns ta l l ed) deteri ora ti on i s obs erved.
Encl os ure Pa nel Acous ti c Foa m I I I R Repl a ce i f cra cked or bri ttl e.
1
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC (18ºF) a bove a mbi ent tempera ture. Legend
Hea ters a re externa l l y powered. Refer to Ca ps tone Mi croturbi ne Hi gh Humi di ty Pa cka ge Appl i ca ti on Gui de
I = Inspect R = Replace
(480035).
C = Clean S = See instructions in this document
Table 6. C200/C1000 Biogas (Fuel Types A, B) Maintenance Schedule – 84K to 160K Hours
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
Air Filtration
440342,
440185,
Injector As s embl i es I R I R I R I R I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440250,
440186
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f da ma ge obs erved
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216 cycl e, a nd Battery Maintenance for recha rge i nterva l s .
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t)
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Electronics and Cables
Powerhea d 440316 R R
Dump Va l ve Hos e a nd Repl a ce when repl a ci ng powerhea d, a nd i f cra cki ng or bri ttl enes s i s
R R
Genera tor Bl ower Hos e obs erved.
Powerhea d Shroud Ora nge Sea l I R I R Repl a ce i f cra cked or bri ttl e.
Si l i cone/Fi bergl a s s Exha us t Sl eeves I R Repl a ce i f da ma ged.
Exha us t Ba ckfl ow Va l ve Sys tems wi th common exha us t onl y. Repl a ce i f da ma ge or
440334 I I I I I I I I I I
(If i ns ta l l ed) deteri ora ti on i s obs erved.
Encl os ure Pa nel Acous ti c Foa m I I I R Repl a ce i f cra cked or bri ttl e.
1
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC (18ºF) a bove a mbi ent tempera ture. Legend
Hea ters a re externa l l y powered. Refer to Ca ps tone Mi croturbi ne Hi gh Humi di ty Pa cka ge Appl i ca ti on Gui de
I = Inspect R = Replace
(480035).
C = Clean S = See instructions in this document
Table 7. C200/C1000 High Pressure Sour Gas (Fuel Type S) Maintenance Schedule – 4K to 80K Hours
Work
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
Air Filtration
Injector As s embl i es 440193 I R I R I R I R I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 8. C200/C1000 High Pressure Sour Gas (Fuel Type S) Maintenance Schedule – 84K to 160K Hours
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
Air Filtration
Injector As s embl i es 440193 I R I R I R I R I R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 9. C200/C1000 Liquid Fuel (Fuel Type D) Maintenance Schedule – 4K to 80K Hours
Work
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
440342,
440185, See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
Air Filtration
Inl i ne Fuel Fi l ter I R I R I R I R I R More frequent repl a cement of fuel fi l ters a nd va l ves ma y i ndi ca te a n
envi ronmenta l , i ns ta l l a ti on, or fuel qua l i ty i s s ue tha t needs to be
Fuel Shutoff Va l ve R R a ddres s ed.
Injector As s embl i es 440317 R R R R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 10. C200/C1000 Liquid Fuel (Fuel Type D) Maintenance Schedule – 84K to 160K Hours
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
440342,
440185, See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
Air Filtration
Inl i ne Fuel Fi l ter I R I R I R I R I R More frequent repl a cement of fuel fi l ters a nd va l ves ma y i ndi ca te a n
envi ronmenta l , i ns ta l l a ti on, or fuel qua l i ty i s s ue tha t needs to be
Fuel Shutoff Va l ve R R a ddres s ed.
Injector As s embl i es 440317 R R R R Ins pect for i njector tube s cori ng or cutti ng, repl a ce i f cut through.
440192,
Igni ter R R R R R R R R R R
440279
440304,
Engi ne Combus tor Li ner I I R I I R Repl a ce i f cra cki ng, wa l l brea ches or other da ma ge obs erved.
440333
Batteries
Repl a ce every 3 yea rs or Refer to Battery Technical Reference (410044) for expected l i fe vs . duty
Ba ttery Pa ck (Dua l Mode onl y) 440216
20,000 hrs of mi croturbi ne opera ti on (whi chever occurs fi rs t) cycl e, a nd Battery Maintenance for recha rge i nterva l s .
Ba y El ectroni cs Fa n a nd EPDB Fa n R R
Powerhead and Other Electronics and Cables
Table 11. Additional C200/C1000 Hazardous Location (HazLoc) Maintenance Tasks Schedule – 4K to 80K Hours
Perform these additional or modified maintenance tasks in addition to those appropriate for the system fuel type.
Work
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Maintenance Component
0
Comments
00
00
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
,0
Instruction
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
4,
8,
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
440342, See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
Es tabl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
Air Filtration and Enclosure
440250,
440186
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC
Anti-Condens a tion Hea ters (18ºF) a bove a mbi ent tempera ture. Hea ters a re externa l l y powered.
Ins pect every 12 months
(Hi gh humi di ty s ys tems onl y) Refer to Capstone Microturbine High Humidity Package Application Guide
(480035).
Ins pect bl a des every 12 months ; s tart wi th both fa ns
Pres s uri za tion Bl ower Ai r Fi l ter I C Start wi th both fa ns a nd veri fy opera tiona l wi th no ra ttl i ng
a nd veri fy opera tiona l wi th no ra ttl i ng
Legend
I = Inspect R = Replace
C = Clean S = See instructions in this document
Table 12. Additional C200/C1000 Hazardous Location (HazLoc) Maintenance Tasks Schedule – 84K to 160K Hours
Perform these additional or modified maintenance tasks in addition to those appropriate for the system fuel type.
Work
10 0
10 0
11 0
11 0
12 0
12 0
12 0
13 0
13 0
14 0
14 0
14 0
15 0
15 0
16 0
0
00
00
00
10 0
Maintenance Component
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
00
Comments
0
,0
,0
,0
,0
Instruction
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
4,
8,
2,
6,
0,
84
88
92
96
Engi ne Ai r Fi l ter 440213
El ectroni cs Ai r Fi l ter 440213
440342, See Site-Specific Air Filter Replacement Interval Evaluation. Cl ea n or
Es tabl i s h s i te-s peci fi c a i r fi l ter a nd hea ts i nk cl ea ni ng i nterva l
440185, repl a ce uni ts a s needed.
IGBT a nd El ectroni c Hea t Si nks
Air Filtration and Enclosure
440250,
440186
Power hea ters ON, wa i t 5 mi nutes . Veri fy a l l hea ters a re a t l ea s t 10ºC
Anti-Condens a tion Hea ters (18ºF) a bove a mbi ent tempera ture. Hea ters a re externa l l y powered.
Ins pect every 12 months
(Hi gh humi di ty s ys tems onl y) Refer to Capstone Microturbine High Humidity Package Application Guide
(480035).
Ins pect bl a des every 12 months ; s tart wi th both fa ns
Pres s uri za tion Bl ower Ai r Fi l ter I C Start wi th both fa ns a nd veri fy opera tiona l wi th no ra ttl i ng
a nd veri fy opera tiona l wi th no ra ttl i ng
Legend
I = Inspect R = Replace
C = Clean S = See instructions in this document
s
ar
ar
ar
ye
ye
ye
Accessory Comments
5
y
y
er
er
er
Ev
Ev
Ev
UPS Battery R
Advanced Power
PLC Battery R
Server (APS)
Cooling Fans R
UPS Battery R
C1000 Controller PLC Battery
Cooling Fans R
UPS Battery R
Capstone Logic PLC Battery R
Controller (CLC) Cooling Fans R
Frame and Engine PMs R
UPS Battery R
PLC Battery R
HazLoc Controller
Cooling Fans R
Frame and Engine PMs R
Heat Trace UPS Battery R
Controller PLC Battery R
UPS Battery R
Hybrid UPS PLC Battery R
(HUPS) Controller Cooling Fans R
Frame and Engine PMs R
Legend
I = Inspect R = Replace
C = Clean S = See instructions in this document
6. Responsibility
It is the responsibility of Capstone to:
Make these procedures available to Authorized Service Providers so they can successfully
complete this task.
It is the responsibility of the Authorized Service Provider to:
Read this document, understand its contents, and effectively complete procedures.
Upon completion of service, submit a Field Service Report (420006) or Interactive Field
Service Report (420006) to [email protected].