Transcript
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
DEAR THE USER OF EMSA GENERATOR;
First of all thank you for choosing Emsa generator. This operating and maintenance manual is prepared and developed to introduce you Emsa generator system. This manual gives general information about installation, operation and maintenance of the generator. Moreover general information, tables and schemas related the generator you have purchased are provided here. Never operate, maintain and repair your generator unless you take safety measures.
2
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
DEAR THE USER OF EMSA GENERATOR;
First of all thank you for choosing Emsa generator. This operating and maintenance manual is prepared and developed to introduce you Emsa generator system. This manual gives general information about installation, operation and maintenance of the generator. Moreover general information, tables and schemas related the generator you have purchased are provided here. Never operate, maintain and repair your generator unless you take safety measures.
2
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
4.13.1 Exhaust silencers ........................... .................................................21 ......................21 4.13.2 cabins .......................... ........................................................ ....................................21 ......21 4.13.3 other sound silencers .......................... ............................................21 ..................21 4.14 Towing of the generator with trailer ......................... ..................................21 .........21 4.14.1 Preparation for towing ............................. ..........................................21 .............21 4.14.2 Towing .............................. ........................................................... ...............................21 ..21 4.14.3 Parking .............................. ........................................................... ...............................21 ..21 4.15 Storage............................... Storage............................................................. ........................................21 ..........21 4.15.1 Storage of motor .................................................21 .................................................21 4.15.2 Storage of alternator................................ alternator............................................21 ............21 4.15.3 Storage of battery .............................. ...............................................21 .................21 4.16 Motor Block water heater .............................. ...............................................21 .................21 5. GENERATOR CARE ........... ........................ .......................... ......................... ......................... ..................22 .....22 6. CONTROLS AND AND PROCESSES TO BE CARRIED CARRIED OUT BEFORE THE STARTING OF THE GENERATOR.................................... GENERATOR.........................................22 .....22 7. GENERATOR CONTROL CONTROL SYSTEMS ........... ........................ .......................... ......................22 .........22 8. OPERATION OF THE GENERATOR......................... GENERATOR...................................... ....................23 .......23 8.1 Operation instruction of automatic generator .......................23 8.1.1 Operation with DKG 307 Control Control Panel ...................23 8.1.2 Operation with EOAM 210FD-FL Control panel ...........23 8.1.3 Operation with AMF 4.0 Control Panel Panel .....................23 8.2 Operation instruction instruction of manuel generator generator ..........................2 ..........................23 3 8.3 Points to be noted while starting up ........................... ...................................23 ........23 9. INTRODUCTION AND OPERATION INSTRUCTION OF AUTOMATIC TRANSFER DEVICE ............ ......................... ......................... ......................... .......................... ......................24 .........24 9.1 DKG 307 Automatic Transfer Device.............................24 9.1.1Digital indications ............................. ...................................................24 ......................24 9.1.2 EOAM 210 FD-FL Automatic Transfer Device: .............24
9.1.3 AMF 4.0 Automatic Transfer Device .......................... ..........................24 24 10. LOCATION AND REPLACEMENT OF POWER BOARD ................26 11. FAILURES OF ALTERNATO ALTERNATORR AND RECOVERY ............ ......................... ................27 ...27 12.FAILURES 12.FAILUR ES OF DIESEL MOTOR AND RECOVERY...........................28 RECOVERY...........................28 13.PERIODIC MAINTENA MAINTENANCE NCE INSTRUCTIO INSTRUCTION N ............ ......................... ......................30 .........30
4
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
1. INTRODUCTION
Emsa Generator is designed to be applied to the circuit immediately wherever it is taken as long as cooling water and its antifreeze, fuel, lubricating oil and charged battery are provided. EMSA manufactures efficient, reliable and high-quality generators by means of experience of long years. This operation and maintenance manual is prepared to help the user about using and performing maintenance of the generator easily. In the event of following recommendations and instructions in this manual, maximum performance and effect can be obtained. In order to ensure regular operation of generator in dirty and dusty environment, it should be noted to maintain more frequently. Settings and repairs should always be performed by authorized and qualified personnel. Every generator, frame has the model and series numbers shown on the label. Moreover, manufacture date, current, voltage, power term of kVa, frequency, power factor and its weight are indicated on this label. This information on the label is necessary for ordering spare parts, processing o guarantee or providing service.
Gen - Set Type
Gen - Set Serial No
Engine Type
Engene Serial No
Alternator Type
Alternator Serial No
Power (kVA)
Voltage (V)
Frequency (Hz.)
Current (A)
Speed (rpm)
Cos Φ
Phase (kg)
Production Year
Nominal Voltage
Weight (kg)
Max. Height
Max Temp.( C)
Performance class EMSA Elektromotor Alternatör San. Tic. A.fi.
Meclis Mah. Teraziler Cad. No:37 Sarıgazi/İstanbul Tel: +90 216 420 00 03 (pbx) Fax: +90 216 364 45 00 e-mail:
[email protected] www.emsa-jenerator.com.tr
Figure 1.1 EMSA Generator Label
5
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
2.SAFETY
(-) pole of battery.
2.1. GENERAL
• Generator must be installed and operated by authorised service personnel in accordance with the standards.
The generator is designed to be safe completely provided to be operated correctly. In addition to this, safety responsibility belongs to the ones who install, operate and maintain the generator. If the safety precautions indicated are applied, the possibility of accident is very low. Ensuring the necessary safety before any technical operations or processes is dependent on the one who performs that operation or process. The generator can only be operated by authorized and qualified personnel.
2.2 INSTALLATION, CARRYING AND TOWING
• Section 4 covers installation, lifting and storage of generator. Read this section before carrying, installing or towing the generator with trailer. Please note the safety precaution stated below. WARNINGS
WARNINGS
• Perform the electrical connections as per the relevant standards. Grounding and grounding failures are included in these standards.
• Please read and understand all warnings in this manual before operating or maintaining the generator.
• Please make sure that fuel storage systems for generators are mounted in accordance with relevant codes, standards and other requirements.
• In the event of not following procedure, instruction and safety precautions in this book, accident and injuring are likely to increase.
• Do not operate the generator in the event of known unsafe condition. • Motor exhaust gases are dangerous for personnel. Exhaust gases of all generators indoors must be disposed with • If there is an unsafe condition in the generator, put danger warning proper, leak proof, black pipes as per the relevant and prevent operation of generator by disconnecting of negative (-) standards. Hot exhaust silencer and exhaust pipes pole of battery until correction of this negative condition. should be protected against being contact with flammable objects and touching of personnel. • Before maintaining and cleaning of generator, disconnect negative Please ensure disposal of exhaust gases out of 6
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
danger.
WARNINGS
• Do not lift up the generator , alternator and motor via lifting rings. • Ventilate the generator room properly. In order to lift up the generator use the lifting points on the frame. (Figure 4.1). • Keep clean the Generator, generator room and the floor. In the event of spilling of fuel, oil, battery electrolyte or cooling water • Make sure that lifting devices and support structures are durable around, clean the spilled area immediately. and have the capacity of bearing the generator. When the Generator is lifted all personnel should be kept away the generator. While • Do not keep flammable liquids near the motor. towing the generator with trailer, you should note all traffic rules, standards and other regulations. Necessary hardware and speed • Do not allow events to cause the combustion limits expresses explicitly in the regulations a re included. such as smoking, flame, spark around fuel. • Before performing connection or disconnection • Do not allow personnel to travel on the mobile generator. Do not of battery connection, disconnect feeding of battery charger. allow personnel to stand on the towing bar or between mobile generator and wrecker. • Keep grounded conductive objects away from areas being exposed to electricity such as terminals, in order to avoid • Unless designed distinctively, do not install and operate the generator arc event. Sparkle or arc may inflame the fuel. in an environment characterized as dangerous. • While motor is working, do not fill the fuel tank. 2.3 FIRE AND EXPLOSION • Do not operate the generator if there is fuel • Fuel and smoke being parts of generator can flame and explode. leakage in the fuel system. Taking proper precautions during the storage of these materials can be reduced fire and explosion risks. Class BC and ABC fire extinguishers • There must be an emergency exit door for must be kept handy. Personnel must know how to use them. personnel's easy existing in the event of any fires. 7
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
cooling water has cooled. Before opening the radiator hole completely, loose the hole slowly for reducing the high steam pressure.
2.4 MECHANIC
Generator is designed with its housings in order to be protected against moving parts. Yet, precaution should be taken to protect personnel and devices against other mechanic hazards while working in the generator room.
2.5 CHEMICAL
Oils, cooling water and battery electrolyte used in the Generator are industrial type. If not used properly, they may harm the personnel.
WARNINGS
• Do not operate the generator in the event of safety housings' are WARNINGS not in place. Do not attempt to reach near or under of safety housing for maintaining or another reason while the generator is working. • Do not contact fuel, oil, cooling water and battery electrolyte with skin and swallow. If • Hand, arm, long hair, jewellery, overhang clothes parts should be swallowed accidentally, seek medical treatment kept away from moving parts of generator. immediately. In the event of contacting with skin, wash contact area with soup and water. Caution: Some moving parts are not seen visibly. • Keep closed and locked the Generator room. • Do not wear clothes contaminated by fuel or oil. While preparing the battery, wear acid-resistant overall, face • Avoid contacting of hot fuel, hot cooling water, mask and safety goggles. In case of spilling of battery electrolyte on hot exhaust gas smoke, hot surfaces and sharp the skin or clothes, clean the area spilled plenty of pressurized water corners. immediately. • Use protective clothes and materials while working at generator site.
2.6 NOISE
• Do not open the cell filler hole of radiator until
Loudness level of generators not being equipped with sound isolation 8
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
cabin is more than 105 dBA. Long term exposure to loudness level more than 85 dBA is dangerous for hearing..
• Do not attempt performing load connecting or disconnecting while standing on wet or watery ground. • Do not contact with conductor, connection cables and electrical parts on the Generator with any parts of your body or any objects not being isolated.
WARNINGS
• Wear headphone while working in the generator site. 2.7 ELECTRICAL
• After performing load connection or disconnecting load, fix the cover of alternator its place. Unless the cover is not fixed securely, do not start up the generator.
Efficiently and secure working of electrical devices is provided with installing, using and maintaining of these devices properly.
• Connect the generator to loads and electric systems conforming to its electrical characteristics and power.
WARNINGS
• Keep all electrical equipment clean and dry. Replace the electrical system where isolation has abraded, cracked and broken. Replace the terminals having abraded, corroded and faded. Keep clean the terminals and perform connections tightly.
• Attaching of generator with the load should be performed by authorised and qualified service personnel in accordance with relevant electric codes and standards.
• Isolate all connections and idle wires.
• Before starting up the Generator, (including mobile generators) make sure that grounding of the generator has been performed.
• Use Class BC or ABC fire extinguisher in case of electric fires.
• Before connecting or disconnecting load to generator, stop operation of the Generator and disconnect the negative (-) terminal of battery. 9
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
2.8 FIRST AID IN CASE OF ELECTRICAL SHOCK CAUTION
via seeing, hearing and feeling.
• Do not touch with bare hand to the person being exposed to the electricity before switching off the electric source.
BLOOD CIRCULATION
• If possible deactivate the electric source. If not, unplug it or move away the electric cable from the one being exposed to the electricity.
IF HE CAN NOT BREATHE BUT THERE IS PULSE
Control the survivor's pulse from his neck. Close the nose of survivor tightly. Unite your lips with survivor's lips via taking deep breath. blow from the mouth observing the rising of thoracic cage. Then permit thoracic cage to go down completely through stopping blowing. Give breath for 10 times average per minute to the survivor. If the survivor is left unattended so as to call for help, come back in a short time with breathing out for 10 times again and continue the action of breathing out. After every breathing out, control the pulse. Position the survivor in recovery position when he starts breathing.
• If they are not possible, stand on dry, non-conducting material, move away the one being exposed to the electricity via using preferably dry wood. • If the survivor breaths, position the survivor as the way described below. • If the person being exposed to electricity has lost his consciousness, perform the treatment stated below to bring round:
IF HE CAN NOT BREATH AND THERE IS NO PULSE
Seek medical assistance or call the nearest health institution. Breath out the survivor for 2 times and start cardiac massage as described below.
DECONGESTING THE RESPIRATORY TRACT
Hang the head of survivor backward and lift up his chin. Remove the objects getting into mouth or throat of the survivor such as false teeth, chewinggum, cigarette.
Position your palm above 2 finger from the junction of thoracic cage.
BREATHING
Control whether the survivor is breathing or not
Position your other hand locking your fingers. 10
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Holding straight your arms press 4-5 cm down 15 times per minute. process and 15 times cardiac message until medical aid comes. condition of the survivor, continue breathing out via controlling his pulse. Control his pulse after every 10 breathing out. As soon as he begins to breath convert him recovery position.
Emsa Generator is designed as a whole to ensure high quality and security. Figure 3.1 shows the main parts of a typical generator. But every generator shows difference as per the configuration and sizes of main components. This section describes parts of generator group in short. More detailed information is provided next sections of this manual. In every generator a label pertaining to that generator is stuck on the frame. (Figure 1.1) This label contains information describing the generator and working characteristics of generator. This information is model number, series number, alternator voltage and frequency, out power as kVA, weight and manufacture date. Model and series number only define that generator and they are necessary in the event of processing of guarantee, demanding service and spare parts.
RECOVERY POSITION
Lay the survivor sideward. So as to ensure the respiratory tract's being open keep his head leaning in such a way that his chin will look towards. Ensure the survivor not to tumble forward and backwards. Control his breathing and pulse regularly. If either of them stops, repeat the actions described above.
3.2 DIESEL MOTOR
Diesel motor (1) driving the generator is chosen since it is manufactured especially for generator and secure. The motor is four-cycle, industrial heavy duty type and all accessories for enduring safe energy are provided on it. Exchangeable dry type air filter, mechanic or electronic engine speed control governor are some of these accessories.
WARNING
• Do not give liquids such as water until the survivor has gained his consciousness again. 3. GENERAL DEFINITION
3.3 MOTOR ELECTRIC SYSTEM
3.1 DESCRIPTION AND DEFINITION OF GENERATOR
Motor electric system is negative grounded 24 ›r 12 v D.C. this system consists of electrical starter motor, battery and battery charge 11
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
alternator.For 12 V electric system one and for 24 V electric system two uncared type starter battery are provided. If desired, other type 3.7 VIBRATION INSULATOR batteries can be provided, too. Batteries are explained in details in Section 4. Vibration insulators (8) are used for preventing the generator's conveying vibration to the ground it has been installed via reducing the vibration of motor. These insulators are placed between motor and alternator stays and frame. If requested, special insulators can 3.4 COOLING SYSTEM be used between frame and ground. Motor cooling system is air cooled or water cooled. An air-cooled system includes a high fan to cool the motor which gives cool air 3.8 SILENCER AND EXHAUST SYSTEM inside of the motor. Water- cooled system consists of radiator (3), fan, recirculation pump and thermostat. There is built-in fan in the Exhaust silencer is provided with the generator and/or separately alternator to cool the winding of alternator. for mounting (2). The silencer and exhaust system reduces the noise spreading from motor and orients the exhaust gas for a safe output. 3.5 ALTERNATOR 3.9 CONTROL SYSTEM Output voltage and power of generator is produced by the alternator (4) which has protected cage IP 21-23 protection Standard (protected Manual or automatic control system and panel (9) are mounted on against particular and dripping), is self-warned, self-regulation, and the generator so as to protect the generator against possible failures, brushless. Terminal box made of steel plate (5) is mounted on the control the operation and output of the generator. Detailed information alternator. on these systems are provided in Section 7. 3.6 FUEL TANK AND FRAME
Motor and alternator are mounted on a steel frame (6). There is fuel tank inside of the frame (7) (see Table 4.2 for capacities of fuel tank). 12
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
5 2
3
1
8
7
4
6
9
Figure 3.1 Typical generator group
1. Diesel Motor 2. Exhaust 3. Radiator 4. Alternator
5. Terminal Box 6. Frame 7. Fuel Tank (inside the frame) 8. Vibration Insulators 13
9. Control Panel
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
4. INSTALLATION, LIFTING AND STORAGE
4.2 CABIN
4.1 GENERAL
When the Generator is put in a cabin, moving and installation will be very easier. Cabin protects the generator against using of unauthorised persons and exterior factors.
After being familiar with dimensions of the Generator, the plan for installation of generator can be arranged. This section includes necessary and important factors for safe and efficient installation of generator.
Figure 4.1 Lifting of generator with crane 14
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
enduring the generator, fuel tank and other accessories. If Generator room is sometimes wet, ground of generator must be elevated. So abrasiveness of frame will have been reduced. 4.6 COMBUSTION VENTILATION
Motor combustion air must be clean and cold as much as possible. Combustion air is drawn from the environment where the generator is via air fitler mounted on the motor. But sometimes air around the generator may not be suitable because of dust, dirt and temperature conditions. Under these circumstances, air inlet channel can be provided. This channel ensures clean air for the air filter on the motor from outside or another room.
Figure 4.2 orienting of air ejecting from radiator with deflection
channels A sharp corner between radiator hot air ejecting channel or funnel should be avoided. (Figure 4.3). to circulate the air ejected outside, directing arrangement should be done. (Figure 4.2).
4.7 COOLING AND VENTILATION
Motor and alternator release heat and cause increasing of ambient temperature. Increasing of temperature affects negatively working of the generator. For this reason, enough ventilation should be provided so as to keep cool motor and alternator. Air flow should be as seen on Figure 4.4. air must enter the generator room by alternator, exist from the room by means of flexible bellows canvas made of tent canvas passing over the motor and through radiator. If a canvas is not used for ejecting hot air out of the room, fan reduces the efficiency of cooling via expanding hot air in the generator room.
Figure 4.3 poor ventilation assembly
Air inlet and output Windows should be large enough for being easy of air inlet to the room and output from the room. Air inlet and output Windows should be larger 1.5 times than radiator area on the basis of a rough estimate. In order not to affect generator by bad weather 16
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
conditions, inlet and output Windows must be louvered Windows. 4.8 EXHAUST These louver may be fixed, but it is preferred that they should be The aim of motor exhaust system is to eject exhaust fumes outside the moving for cold climates. Louvers can be closed while generator is room in order not to cause danger and discomfort and reduce the not operated. So hot air facilitiating first starting up and providing noise. So as to reduce loudness level of motor a proper exhaust to the load stays in the room. Louvers can be moved automatically silencer should be fixed to the exhaust pipe. if they are moving in a generator room having automatic control WARNINGS system. By this means, louver can be opened immediately after motor • It is dangerous to inhale motor exhaust gas. Gases of all generator starts to operate and closed immediately after the motor stops. in the closed area must be ejected with leak proof pipes in accordance with standards. • Keep away hot exhaust silencer and exhaust pipe from flammable materials and ensure them to be protected for the safety of personnel. • It is noted when designing the exhaust system that back pressure shall not exceed the pressure values instructed by the motor manufacture. Excessive back pressure causes motor to be damaged. In order to reduce back pressure, exhaust pipes must be short and flat as much as possible. Every necessary elbow must have arc at least 1.5 times radius more than inner diameter of pipe. It will be good to use 1 inch larger pipe diameter at every 6 meters or 3 elbows for reducing exhaust back pressure. • In order to prevent conveying of motor vibration to exhaust pipe system and building, and due to the expansion resulting from heating, a flexible connection between exhaust manifold and exhaust pipe system. • Weight of exhaust pipe should be supported by surrounding structure for not being weight for motor manifold. Weight of exhaust Figure 4.4 Basement floor plan of typical Generator group 17
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
t e l n i r i a . s f r o o t s a i e z d i s a . , m r s o e t o e z . r i o s r r m e t o e t m e a R o r m o h e r i t a i , d n s e e g w s s t z t i s u a p u a r o d r o h x t e g e d a f t r i e v o o u o n s r e p b g e r l s a u r r s e e e l s a e e t a i e e l d m d e e r d h t p u y n o t a e y s e n t s l e w p e u s o s o d n a n a i e o c s l p e m s E W t a 5 u . l 1 e . t p 4 P 4 u e : o r e e l u t b d g o a n i T a F N 18
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
system should be given to the building. Tensile element can be used 4.9 FUEL SYSTEM for this. • Generator room should be isolated for loudness level of exhaust Generator fuel system should continuously clean fuel for the motor. parts and heat released. Silencer and exhaust pipes should be placed The fuel system consists of daily fuel tank, fuel hoses and main fuel away from flammable materials. tank. • Opposite weights flap type rain covers can be used for preventing rain inlet to exposed exhaust outputs with different applications. WARNINGS • Every generator must have its own exhaust system. Exhaust outputs of generators can not be connect using only one exhaust pipe. • Fuel storage systems of Generators must conform • Exhaust material should be of metal pipe. to standards. • Do not allow events being likely to cause fires such as flame, sparkle or smoking around the fuel. 4.8.1 DIMENSIONS OF GENERATOR ROOM 4.9.1 Daily fuel tank: Daily fuel tank keeps the daily fuel that generator needs ready to use. For this reason, daily fuel tank should be at generator room. Steel frame of generator is manufactured as tank-frame to store daily fuel tank. (up to 880 kVA). Note: For larger force please consult your authorised sales representative
(Table 4.2). 4.9.2 Main fuel tank:
The main fuel tank can be installed in addition to daily fuel tank for providing operation of Generator longer. Main fuel tank should be placed somewhere outside the room so as to perform filling and maintenance easily. But since at cold
Figure 4.5 Generator room 19
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
l e u f d n a s p u o r g r o t a r e n e G o t g n i n i a t r e p s e i t i c a . p d a c a o l k l n a f u t l t e u a F n o i t 2 . p 4 m e u l s b n a o T c 20
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
atmospheres fuel flow is restricted with increasing of viscosity, main fuel tank should not be left at excessive cold atmosphere. In order to reduce vaporization, expansion or air pressure occurring during the fuel filling to the tank, vent output should be mounted on the tank. This vent output prevents vacuum forming in the tank during fuel consumption. Bottom of fuel tank should have slope. So it prevents fuel tank to damage via ensuring accumulating of water and hoses at one point. A drain valve should be placed the lowest point of fuel tank to discharge water and deposit.
WARNINGS
• Do not use galvanized pipe for fuel system. • Do not fill fuel tank completely. Leave a gap as 6% of fuel tank capacity for allowing expansion of fuel at high ambient temperature. • There should not be natural flow from fuel pipes to motor because of gravity when the motor stops. • Fuel temperature is a critical factor for proper motor operation. Since fuel heat more than 71°C decreases heat content per volume because of expansion, motor output power decreases.
4.9.3 Fuel channel:
Materials conforming with fuel such as Black, steel pipes or flexible hoses can be used for fuel piping. In order to avoid leakage and damages caused by motor vibration, flexible fuel hoses must be secured between motor and fuel tank. Fuel feeder line should take the fuel at least 50 mm above from the bottom of fuel tank and from a point far away from fuel return line.
• Connection pipe from main fuel tank to daily fuel tank should be bigger than or equal to daily tank feeder pipe. • Using water separator pre-filter in fuel system line will protect injections and fuel pump.
FUEL PIPE RECOMMENDATIONS Generator Stand By Power (kVA) 0-800 800-1500 1500-2200
Maximum Length of fuel pipe (m) 6 6 6
Maximum vertical height (m) 0,9 0,9 0,9
Maximum number of pipe Fittings Elements 6 6 6
Recommended pipe diameter (inch) 1" 1 1/2" 2"
• Main fuel tank can be higher or lower than daily fuel tank. For fuel tank applications to be mounted as per Standby generator groups, it is necessary to apply positive static fuel pressure to fuel pump inlet.
Table. 3 Table of recommended pipe diameter of fuel installation 21
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Figure 4.6 Typical general fuel piping mounting of fuel from main fuel tank to daily fuel tank
1. Filli ng Cabin 2. Filling line to main fuel tank 3. Ventilation shaft 4. Main fuel tank level indication 5. Main fuel tank 6. Drain valve 7. Fuel-liquid accumulation tank 8. Output valve 9. Feeder line leading to daily fuel tank 10. Electrical fuel transfer pump
11. Electrical fuel shutoff valve 12. Fuel-liquid accumulation tank 13. Daily fuel tank (in the frame) 14. Fuel level control switches 15. Manual filling and for air 16. Fuel level indication 17. Drain valve 18. Fuel leakage alarm 19. Motor fuel filter 20. Motor fuel pump 22
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Figure 4.7 Typical fuel diagram placed below the fuel tank motor
Check valves should be used in case of the fuel tank is 2 m above from crankshaft center. Maximum fuel level cannot exceed 2 m above crankshaft center and minimum fuel level should be above 15 m from fuel injection pump. If fuel level exceeds 2 m. The motor can be damaged. If fuel level is below 15 cm. proper fuel pressure can not be provided at fuel pump inlet. In another way, tank fuel level should not be above the injection and below more than 80 cm from fuel pump. Figure 4.7) If fuel tank is raised above about 1.5 m height from Injections, (Figure 4.8) it is placed for protecting motor against hydraulic locking as the same with 2 pieces check valve. The protection capacity of these valves is from 0 to 1.5 m height. If fuel tank is to be above more than 1.5 m float m float tank should be placed. Tank mounted far away and at a higher point is shown. (Figure 4.9) under motor level fuel tank placed far is shown, also (Figure 4.10).
Figure 4.8 Fuel tank and check valve connection put about 1500
mm above from fuel return
Figure 4.9 Float tank used with elevated fuel tank 23
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
While adding water to your radiator, minimum 35% antifreeze should be added. Using antifreeze water in your motor during summer and winter is very important for motor life and water channels.
Figure 4.10 Fuel tank placed below 1500 mm 4.10. OIL AND ANTIFREEZE USED IN GENERATOR
Lubrication system of diesel motors is one of the most important parts of the motor. Exact motor care (oil replacement period, filter replacement period and noting sufficiently for oil type used) prolongs motor life and reduces usage cost of motor. Recommended oil;
4.11 BATTERIES 4.11.1 WELL-KEPT TYPE BATTERIES: WARNINGS
15W40 Turbo Diesel, Antifreeze Super 4 season.
Do not allow events to cause combustion such as flame, sparkle, smoking around the batteries. While preparing battery wear an overall resistant to acid, face mask and safety goggles. In case of spilling of battery electrolyte on skin or clothes, clean the spilled area with plenty of pressurized water immediately. Take off jewellery objects in your hand and wrist such as chain, ring before using
4.10.1. Viscosity -temperature diagram:
You can control the conformity of oil you use with temperature in your area by means of following chart. The antifreeze is not placed in radiator of your set as factory- exit. 24
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
1.2201 230 half charged with specific gravity 1.150 1.220 specific gravity discharged.
Since it is not possible to produce harmonics and predict the quantity in advance during planning stage of installations, neutral conductors should either be dimensioned as high values or cross-section of neutral conductor should be at leas as phase conductor cross-section. Another point that needs to be noted about selection of cable is whether there is load with demurrage (such as electric motor) and distance between load and generator. At low voltage network, it the distance is very long since current drop will increase very much during demurrage voltage may drop undesired levels. To prevent this, load table with more suitable cross-section can be chosen by means of the formula below.
4.11.2 Uncared type batteries:
Make sure that electrical connections are correct and batteries have charge. Except from it, these batteries do not require any maintenance. 4.12 ELECTRICAL CONNECTIONS:
Electrical connections and their maintenance must be performed by qualified and experienced authorised service personnel. WARNING
• Perform electric connections in accordance with relevant electric codes and standards.
∆u = √3 x L x I ( R Cos + X Sin ) ∆u = absolute voltage drop (Volt) L= Length of line (m) I= line current (A) R= resistance of cable (ohm/m) X= resistance of cable (ohm/m) If the distance is short at low voltage Networks;
4.12.1 Wiring:
Electrical connections must be carried out with flexible cables due to the vibration on the Generator. Cables should be located in cable channels and generator should be in accordance with output voltage and current. While deciding about cable cut, tolerances for ambient temperature, installation method, adjacency to other cables will be given. Moreover, cables should be chosen as per TSE or VDE standards. Correctness of all cables must be controlled carefully. Cable cross-sections as per current capacities and generator powers are stated below. ( table 4.5, table 4.6)
If current is known, = the formula
1,73.L.I.Cosø
k.∆u L.P
with
If power is known, = k.∆u you can choose load cable withproper crosssectionwith this formula. 26
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
TN type Networks are the most widespread used network kind nowadays. The star point of this kind of network is grounded. Housing and metal parts of devices are secured to protection conductor PE. PE is also connected with grounded part in its star point. In the event of contact between phase-ground, voltages against ground of PE or PEN protection lines and connected devices increase. Keeping lower than 2 ohm this value of these voltages RB resistance, desired value, namely, a value which is under the allowed contact voltage can be obtained.
• Electrode type to be used in the grounding is established. • Short circuit current of installations and opening time of protection elements to be connected to the system are determined. • Spread resistance is calculated. • Grounding conductor cross section calculation is carried out. • The accuracy of selection and calculation is examined. • The conformity of system in question is searched via calculating step and contact voltage. Before commissioning, all conductors and connection points are controlled visually. Grounding resistance should be Rt < 4 ohm. If this value can not obtained, processes stated above should be repeated and ground resistance value should be made proper. The most important subject while grounding in the generator system is that the distance between network grounding area and generator grounding area should be at least 20 m. This distance is for preventing affecting of grounding system each other. Distance between stick most used for grounding and the stick used for performed grounding and their length are important. In grounding systems performed with more than one stick grounding the distance of sticks' penetrating should be at least distance of two sticks. In a grounding used 1,5 m long stick The other stick should be penetrated at least 3 m distance forward than the first penetrated stick.
Figure 4.11 TN Type network
In projecting of grounding installations: • The place of grounding installations is determined. • Measurement processes are performed for determining of ground specific resistance. 28
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
operated. In the event of waiting of generator for prolonged time without operated, test insulation resistance of windings. Meanwhile, all connections with the aim o control and automatic voltage regulator connection (AVR) should be isolated. Rotating diode should be shorted or disconnected. Megger of 500 V or a similar measurement tool can be used. Connect Megger between output terminal and ground (frame). Insulation resistance should be 1 MΩ more than the ground. In case of insulation resistance is less than 1 MΩ, alternator windings should be dried. CROSS SECTION
mm2
The housing of generator should specially be grounded. In order to prevent breakage to occur due to the vibration, the ground connection should be flexible. Grounding cables should meet the standards and have the capacity at least bearing full load current. 4.12.6 Parallel operation:
Extra fittings should be secured for operating a Standard generator with other generators or network in parallel way. 4.12.7 Insulation test:
Insulation test should be carried out in the event that generators purchased from our company waits for prolonged time without 29
CURRENT CAPACITY
GROUND
AIR
4 x 2.5 4x4 4x6 4 x 10 4 x 16 3 x 25/16 3 x 35/16 3 x 50/25 3 x 70/35 3 x 95/50
36 46 58 77 100 130 155 185 230 275
25 34 44 60 80 105 130 160 200 245
3 x 120/70 3 x 150/70 3 x 185/70 3 x 240/120
315 355 400 465
285 325 370 435
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Table 4.5 Cable cross sections of proper cables as per current
in case of conditions such a loose nut, spun metal, crack, abrasion, excessive tear. Please control the conditions of all tires. Control working of all flash lights and headlights.
bearing capacity and in accordance with PVC isolated YVV (NYY) 0.6/1 KV VDE norms and TSE 4.13 SOUND SILENCER
Today controlling noise of generator is getting more and more important. To control the sound level of generator, there are many equipments.
4.14.2 Towing:
WARNINGS
WARNINGS
Do not forget that while towing generator with trailer, weight of trailer may affect the manoeuvre and stopping distance. • While towing the generator with trailer all traffic rules, standards and other regulations should be observed. Necessary hardware and speed limits expresses explicitly in the regulations are included. Do not allow personnel to travel on the mobile generator. • Do not allow personnel to stand on the towing bar or between mobile generator and wrecker. • Avoid barriers such as slopped and soft land and hole, stone, etc. • Make sure that ground behind the mobile generator and under it are clean while manoeuvring backwards.
• While working at generator site, please wear headphone. 4.13.1 Exhaust silencer:
Exhaust silencer reduces the sound level coming from the motor (section 4.8). 4.13.2 Cabins:
Sound isolation cabins reduce loudness level of generator. 4.13.3 other sound silencer:
Other equipment such as Sound louvers, fan silencer, sound absorbing walls can be used indoors. They reduce the loudness level of generator.
4.14.3 Parking:
Park generator with trailer on a dry ground to be able to bear the weight of generator. If it is parked on a slopped ground, park as crossed to the slope to prevent its being towards downward. Do not park on a ground that exceeds 15°.
4.14 TOWING OF GENERATOR WITH TRAILER 4.14.1 Preparation for towing:
All connection elements on wrecker and generator should be checked 30
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
r e w o p r o t a r e n e G e h t r e p s a e l b a t n o i t c e l e s e l b a C 6 . 4 e l b a T
31
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
4.15 STORAGE
5. MAINTENANCE OF GENERATOR Long term storage of Motor and alternator may have harmful effects. These effects can be reduced minimum via preparing and storing A good maintenance program extends service life of generator. generator in proper way. When and which maintenance should be performed on the generator is indicated on periodic maintenance chart. Periodic maintenance chart is provided with every generator. Maintenance and repairs 4.15.1 Storage of Motor: A motor protection procedure including cleaning motor and protective should be performed only by authorised and qualified service liquids can be applied. personnel. Results of maintenance and repairs having performed should be recorded on Periodic maintenance chart. Generally the generator must always be kept clean. Do not allow materials such 4.15.2 Storage of Alternator: During Alternator storage, moisture occurs in the windings. In order as water, fuel and oil to accumulate in and on the generator. Always to reduce this moisture, store the generator in a dry place. To dry keep clean ground of Generator. the windings, if it is possible heat air. Alternator which has not been used for prolonged time, must have insulation test.( section 4.12.8). 6. CONTROLS AND PROCESSES TO BE CARRIED OUT BEFORE THE STARTING OF THE GENERATOR 4.15.3 Storage of battery: The battery must be controlled every 8 week while storing, if necessary • Examine motor and generator visually as general. Ensure easy air it must be charged completely. suction to the generator site somewhere determined. • Look at the water level via opening radiator cap. If it is missing, add some water. Water level should not ve 30 mm below water 4.16 MOTOR BLOCK WATER HEATING For staring up the motor and taking the load on it, heater of block filling gland. (roundabout) water is used. The heater warms roundabout water • Antifreeze must be available in cooling water of motor even as while generator is not working. For this reason, the heater must be per the coldest weather conditions of the region. Mixing of 50% activated in every season. There are block water heater in generators antifreeze and 50% water will ensure proper protection in every activating automatically. It is optional in manual generators. region. • Please check the air filter indication. If need change to air filter element.Keep opened window louvers of radiator. 32
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
installation in 7-8 seconds. In the event of turning of network voltage 8.2. Operation instruction of manuel generator or entering the usual limits, the system begin to feed from the network in two minutes. The motor of generator Works for two minutes for its 1. Turn contact switch from '0' position to '1' position. (Figure 8.1) own cooling and stops. 2. Meanwhile, oil pressure failure and charge warning light will go on. 8.1.3 Operation with AMF 4.0 Control panel: 3. Then turn starter switch to 'START' position (like starting up a car). 1. Turn the automatic transfer device (AMF 4.0) located on the front Motor of Generator will start working. After starting of motor, let panel of generator to AUTO(automatic). starter switch. 2. While network voltage is within normal limits, generator is in stand- 4. Check whether warning lights on the panel go on and values on by mode. If one of the network phases are cut or network voltage the indications are normal or not. drops excessively, the generator will step in and start feeding the 5. Operate the generator in idling status for about 1 minute. During installation in 7-8 seconds. In the event of turning of network voltage this period the motor will get heated. 6. Meanwhile, receivers (loads) on the installation must be turned or entering the usual limits, the system begin to feed from the network in a minute. The motor of generator Works for one minute off. , for its own cooling and stops. 7. Turn main switch to '1' position. 8. Turn inverter switch from “NETWORK” position to 'GENERATOR' position. 9. Engage receivers one by one. 10. Check amperage and voltage on the phases via using amper meter and voltmeter commutator. 11. Turn inverter switch to “NETWORK” when the network returns. 12. Operate generator at idle position for 1 minute to cool. Then turn starter switch to “0” position. 8.3 Points to be noted while starting up:
It is important that load distribution on phases is balanced for both manual and automatic remote control generator so as to ensure
Figure 8.1 34
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
operation of generator without problems. It is the user's responsibility that load distribution among phases will remain between -/+ 15% tolerance values. Failures resulting from insufficient and/or deficient maintenance are not within the scope of guarantee.
The following are read on these indications : - Measured parameters, - Service counters, - Statistical counters, - Program parameters.
9. INTRODUCTION AND OPERATING INSTRUCTIONS OF AUTOMATIC TRANSFER DEVICES: 9.1 DKG 307 Automatic Transfer Device:
The device is control and protection panel to be designed for used in the generators. It shows values that it has measured on the screen. Programmed parameters are stored on a nondeletable memory in such a way that they will not be affected by power cut. MEASURED PARAMETERS
Voltages between Network Phase-Neutral (R-N,S-N,T-N) Voltages between Network Phase-Phase (R-S,R-T,S-T) Voltages between Generator Phase-Neutral (U-N,V-N,W-N) Voltages between Generator Phase-Phase (U-V,W-V,U-W) Generator phase currents (I) Generator phase voltage (V) Generator phase power (W) Generator frequency (Hz) Generator total active power (kW) Generator power coefficient (Cos ’) battery voltage Temperature of cooling water Oil pressure Introduction:
There are 3 pieces, 7 segment LED type indications on the device.
Figure 9.1 35
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Value of Program parameter is read o this indication during program position.
9.1.1.1 Digital Indications: (1) VOLTAGE INDICATION:
Following values can be read on this indication:
(4)ALARM MUTE:
- During operation from Network, (R) phase voltage - During operation from Generator,(U) phase voltage
(5) MENU:
Alarm silencing.
Browsing of measured values of indications can be done pressing MENU key. If MENU key is held pressing for one second, service counters are accessed.
By pressing MENU button, following values can be read separately: - Voltages between (R-S-T) network phase-neutral - Voltages between (U-V-W) generator phase-neutral - Voltages between (RS-ST-TR) network phase -phase - Voltages between (UV-VW-WU) generator phase-phase If service counters are read, the name of counter is read on this indication. At programming location, (PGM) is read.
(6) LAMP TEST:
Lamp test.
(7) AUTO:
When pressed Auto key, the generator changes to automatic operation mode and LED on the upper side lights. When this key is pressed, generator operates automatically when network electricity is cut and when it returns, it stops.
(2) CURRENT INDICATION:
Measured over current transformer phase currents can be read on this indication. Current transformers between 10/5A and 9000/5A can be used by means of programming. Program number is read here during program position.
(8) OFF:
It is used for switching off generator whose switch off key is in operation. While this key is pressed, generator does not step in automatically.
(3) MULTI FUNCTIONAL INDICATION:
Following values can be read on this indication pressing MENU key. - Generator frequency (Hz) - Generator cos ’ - Generator active power (KW) - oil pressure (bar) - Temperature of cooling liquid (∞C) - battery voltage (V DC)
(9) TEST:
Test key is for operating generator for the purpose of test when there is network electricity. When Generator is operated with this key, automatic control unit does not command connectors. When pressed this key, LED on the upper side lights. 36
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
(10) LOAD TEST:
STOPPING ERROR LED:
Load test is adjusted by authorised service dependent on the request.
If motor does not stop at the end of adjusted stop period, it occurs.
(11) ALARM LEDs:
OVERLOAD LED: Alarms Works as per the first coming principle; according to this; It occurs exceeding programmed limits of one of the generator phase - If there is any alarm, next coming alarms and warnings are not current or active power of generator. included in the process. - If there is any warning, next coming warnings are not considered. VOLTAGE LED: It occurs in the event of exceeding limits of at least one of U-V-W Alarms can be of locking or non locking type as per the programming. phase voltages. For locking alarms, alarm lights remains lighting even if the reason of alarm has been eliminated and they prevent generator's working. LEVEL LED: To delete alarms, any of working patterns is pressed (AUTO-OFF- It is available with some models. TEST-LOAD TEST) BATTERY LED: It occurs when battery voltages exceeds programmed levels or OIL LED: It goes on when motor oil pressure goes down a dangerous level. decreases below them. During the starter, this error is not controlled. If this LED goes on while the generator is not working, oil pressure switch may be defective. CHARGE LED: It lights up in case of failure of charge alternator or belt breaking. HEAT LED: RECTIFIER FAILURE LED: It occurs when a signal comes from excessive temperature contact or when measure value at temperature switch exceeds the adjusted It occurs when signal comes from rectifier failure inlet. limit. EMERGENCY STOP LED: It occurs when he signal comes from emergency stop contact. FREQUENCY LED: It occurs resulting from exceeding programmed limits of Generator circuit. (over speed /under speed) SPARE LED: It occurs when the signal comes from any of spare failure contacts. STARTER FAILURE LED: SERVICE TIME LED: If generator does not operate at the end of programmed starter number, this alarm occurs. This LED is used for helping to perform periodic service of generator regularly. Periodic service is carried out when a certain motor time 37
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
has completed.
Generator power factor (pF)
LED indications: There are 29 LEDs within 4 group on the device. - Group 1: Working way: It shows function of the Generator. - Group 2:Mimic diagram: it shows status of Network and generator
Engine RPM Real Time Error mesages Battery voltage Coolant temperature Oil pressure
voltages and connectors. - Group 3: Warnings and alarms: It shows abnormal conditions experienced during working. - Group 4: unit: It indicates the unit of value shown on the lower indication. 9.1.2 EOAM 210 FD-FL Automatic Transfer Device:
The device is a control and protection panel designed to be used in automatic generators. It show values that it has measured on the display. Programmed parameters are stored on a nondeletable memory in such a way that they will not be affected by power cut. MEASURED PARAMETERS
Voltages between Network Phase-Neutral (R-N,S-N,T-N) Voltages between Network Phase-Phase (R-S,R-T,S-T) Voltages between Generator Phase-Neutral (U-N,V-N,W-N) Voltages between Generator Phase-Phase (U-V,W-V,U-W) Generator phase currents (I) Generator phase voltages (V) Generator phase power (W) Generator frequency (Hz) Generator kVAh Generator Kwh Generator kVAr Charge generator voltage
EOAM 210 FD Figure 9.2 38
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Introduction: (1) The red LED indicates that Mains voltage is displayed.
(14) The red LED shows that the unit is in the MANUEL mode.
(2) The red LED indicates that Generator voltage is displayed.
(15) This button indicates that Mains or Generator voltage is displayed
voltages.
(3) The green LED indicates that Mains voltage and frequency is
within limits and is ready to take over the load.
(16) This button selects either Phase-Neutral or Phase-Phase voltages.
(4) The LED shows that the load is connected to the mains. It's colour
(17) This button closes the mains contactor, only operative when
(5) The LED shows that the load is supplied from the generator. It's
(18) This button opens the mains contactor, only operative when
(6) The green LED indicates that Generator voltage are within limits
(19) This button closes the generator contactor, only operative when
(7) The green LED indicates that the engine has started and is running.
(20) This button opens the generator contactor, only operative when
is green.
manuel mode is selected.
colour is green.
manuel mode is selected.
and is ready to take over the load.
manuel mode is selected. manuel mode is selected.
(8) In the MAN, AUTO and TEST modes, this LED indicates that the
engine has starting up or is running.
(21) The START button is used for starting the engine when the unit
is in manuel mode.
(9) In the MAN, AUTO and TEST modes, this LED indicates that the
engine has stopping or stopped.
(22) The STOP button is used for stopping the engine when the unit
is in the manuel mode.
(10) The red LED illuminates only when the unit in the programming
mode.
(23) When this button is pressed, the unit goes into its programming
mode.
(11) The red LED shows that the unit is in the OFF mode.
(27) The LAMP TEST button illuminates all LED indicators and display
(12) The red LED shows that the unit is in the AUTO mode.
segments.
(13) The red LED shows that the unit is in the TEST mode.
(28) This button will silence the alarm horn after a failure has been 39
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
detected.
MEASURED PARAMETERS
(29) This button will reset the controller after a failure has been
Voltages between Network Phase-Neutral (R-N,S-N,T-N) Voltages between Network Phase-Phase (R-S,R-T,S-T) Voltages between generator Phase-Neutral (U-N,V-N,W-N) Voltages between Generator Phase-Phase (U-V,W-V,U-W) Generator phase currents) Generator phase voltages(V) Generator phase power (W) Generator frequency (Hz) battery voltage temperature of cooling water oil pressure
detected.
(30) The OFF button is used for changing operating mode of the unit
to the OFF mode.
(31) The AUTO button is used for changing operating mode of the
unit to the AUTO mode.
(32) The TEST button is used for changing operating mode of the
unit to the TEST mode.
(33) The MANUEL button is used for changing operating mode of
the unit to the MANUEL mode.
Introduction:
(35-36-37) The display shows LOAD Amp.
(1)pre-heating:
(38) The display shows Mains or Generator voltages.
When motor is not starting under cold weather conditions, it is tried to start motor via performing pre-heating.
(39) Failure indicators.
It operates when only in manual mode and motor is stopping.
9.1.3 AMF 4.0 Automatic Transfer Device:
(START) Starting button:
It is used for providing starting for motor. It operates only in manual mode and when motor stops. “Str” is written on the screen during the starting time of panel.
It a microprocessor-controlled device that monitors one or three-phase network voltage, transfers load between network and generator and controls of failure. When holding pressed of Menu key for 3 sn, 98 parameters related with the operation of the device are adjusted digitally and stored in the memory separately.
40
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
(3) Network contactor:
It controls the contactor that enables the load to be fed by the network. If LED is going on it means that contactor is off and load is feeding from network. NOTE: Generator contactor is locked electrically with network
contactor. Both of these contactors can not be turned off at the same time. (4) Generator Status LED:
When it goes off it means that generator is stable. When it goes on it means that generator is working. If LED is flashing, it means that generator is in the period of cooling and stopping. (5) Network Status LED. :
When it does not go on, it means that network voltage has exceeded the limits indicated with parameters. When it goes on it means that network is within normal values. If LED is flashing, it means delay times when network passes from normal statutes to network failure or from failure to normal status.
Figure 9.3 (STOP) Stopping button:
It is used for the purpose of stopping Motor. It is not matter in which mode is used, when it is pressed, it takes generator to manual mode (6) Failure LEDs: and begins to cooling if generator has taken load before of if the Detailed information about these failures are provided in the following load has not been taken it starts stopping process. During cooling, sections. if stop key is pressed done more generator will stop. (7) Analog oil pressure and over heating indications: In this part, values read by indication points of oil pressure and (2) Generator Contactor: It provides transferring of produced energy to the load after Generator overheating switches are printed on the screen as bar graphics in has began to work. The status of contactor is indicated via LED on such a way that the user can easily see.For overheating, the dial it. If LED is going on, contactor is off and it means that load is feeding starts from 50 C to 100 C, for oil pressure the dial can go the highest from generator. To be turned off contactor of network needs to be value that the switch can be read from starting low oil pressure failure on. level adjusted in parameters. 41
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
selection mode will start flashing when these keys are pressed for the first time. When it is pressed for the second time the value of indication is changed. To change th indication in the selection mode, menu key should be pressed while LED next to the indication is flashing. After switching one of the parameters on the parameter menu via pressing “ENTER” key to adjustment mode, every order of Parameter value can be adjusted the desired number with the help of up/down keys.
(8) Measurement mode selection button:
It selects if frequency and voltage values shown on 2 screens will belong to generator or network. It indicates that whether measurement values shown via LEDs next to it belongs to network 'MA‹NS' or generator 'GEN'. Esc Key:
This button has many functions. In the event of failure, horn is silenced at the first pressing. At the second pressing failure is deleted. It is used for exiting from parameter menu. For this process, it needs to be held pressed for 3 seconds. If the value entered during changing of any parameter in parameter menu, it is cancelled via this key.
(9) Selection of working mode button:
The system can be operated as manual (hand symbol), automatic (letter A) or test mode via three keys located at the right of Panel. The mode of system can be seen via LED next to it. FAILURE AND WARNINGS:
(ENTER) Menu Key:
This button has many functions. It provides selection of values to be shown on the indications at the left side of panel. Under normal operating status, when menu key is pressed for the first time LED next to the indication in the selection mode will start flashing. Then value to be shown on this indication will be changed via down/up keys. It provides entering parameter menu. It is used for changing any values on the parameter menu.
Low High speed failure: This failure occurs when
alternator goes out of limits of frequency of electricity that it has produced. Low High speed Voltage failure: This failure occurs
when electricity produced by the alternator goes out of the voltage values.
(+,-) Up, Down keys:
Overheating Failure:
Under normal operating condition, LED next to the indication in the 42
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Active functions in the system is emergency stop inlet and water level failure inlet. In the event that emergency stop button is pressed A3 is written on the indication and AUX failure LED goes on. In case of a failure in radiator water level, the indication writes A4 and AUX LED goes on.
Over current Failure:
Periodic service time warning: This warning is provided when adjusted after resetting of service time periodic service time has passed. Resetting process is done by the service. Stop working Failure: It means that when this failure occurs generator has not been starts up or stopped. During the starting up generator, if oil pressure, charge or alternator voltage are perceived, oil pressure, charge or low high voltage LED go on together with stop working failure LED. So, the user can understand generator does not work due to the signals.
Devices of control panel: (22) Charge warning lamp: When lamp turns on it means that
battery charge alternator charges less than normal and there is a problem. (23) Working hour: It shows how many hours your set has worked.
Low oil pressure Failure:
(24) emergency Stop Button: It provides your set to be stopped Charge Failure: This failure occurs in the event that
voltage in the end ›f charge failure of charge alternator drops.
immediately in case of emergency. It should not be used except emergency. After performing stopping via pressing the button, getting back should be provided via turning slightly right.
Battery Voltage low high Failure: It occurs when
NOTE: The button is located on the cabin at sets with cabin.
battery voltage goes down or up adjusted limits. Spare failure LED: If functions of spare inlet are
selected as yellow or red, this failure occurs when the inlet is active. 43
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
10. LOCATION AND INSTALLATION OF FORCE PANEL
The points to be noted during the installation ot force panel (transfer switch) are stated below. 1. Mount the force panel as close as main distribution panel. 2. The panel should be located in place which is clean, dry, well-
ventilating and far away from excessive heat. 3. there should be enough working space around the panel. Covers
of panel must be easily opened and panel should be easily interfered. 4. Values of currents drawn from generator should be distributed to
three phases equally as much as possible. Maximum difference between phases must be 15%. 5. current bearing capacities of force cables to be used for generators
are indicated on table 4.6.
6. In order to function properly, operation connection of generator
must be performed correctly. The pattern of this connection is shown at Figure 10.1. there are two cable entries to the panel. One of them is network entry for the control of network and the other one is the output of generator. Network line from meter output or if any network line from compensation panel are transmitted to the receiver over network. Connecting of generator after the meter should be noted.
Figure 9.4 44
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
11. ALTERNATOR FAILURES AND REPAIR FAILURE:
Alternator does not produce voltage. CAUSE: a)Loss of residual magnetism at Stator windings.
- If alternator warning is without winding, contact the same poles of dry battery of 9.5 V to + and - poles of connector at the connector poles numbered 2 and 3 for 5 seconds. If Alternator warning is of winding, contact the same poles of dry battery of 9.5 V to + and - poles of connector at the connector poles numbered 1 and 4 for 5 seconds. b)There are loose contact at panel and connector connections.
-Opening cover of panel, control whether cable ends have pulled out or not and in the same manner, control whether connector ends have pulled out or not. c)There is disconnection at warning button.
- control all connections especially alternator series connector connections. d) There is failures at rotating diode.
-Test diodes one by one with diode parts of AVO meter and replace
Figure 10.1 45
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
damaged diodes. FAILURE: 3-Voltage is increasing as the Alternator is loaded.
e)Cycle of drive machine is very low.
- Increase the cycle of drive machine to the nominal.
CAUSE: f)Regulator card is defective.
-change the card that does not perform regulation.
a)There are motors rotating reversely in the circuit.
-Replace the location of Generator output cables. FAILURE: FAILURE: 2-Voltage drops as Alternator is being loaded.
4-Voltage of Generator is very high.
CAUSE:
CAUSE:
a)Regulator card is defective.
a)One of ends of regulator experiencing phase is disconnected.
- Adjust regulator potentiometer and output voltage to 400 V at idling. After this adjustment, if voltage decreases as loaded, replace the card.
-control connector connections. b)There is disconnection at Voltage adjustment potentiometer.
-Control the ends of potentiometer. b) Cycle drop of drive machine is very much.
-Control the power of drive machine.
c)Regulator card is defective.
-Replace the card that does not perform regulation. c) It is loaded over Alternator power.
-do not load over nominal. d)Rotating diodes are defective. -Control diodes with AVO meter. Replace the defective ones.
FAILURE: 5-Voltage is not read from one or two phases. 46
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
a)Regulator card does not perform regulation function.
CAUSE
- Replace the regulator card.
a)There are disconnections at the end of Voltage control commutator.
-Control the ends of commutator.
b)There are short-circuit at windings.
-Control windings with AVO meter via opening connector box. If there is resistance difference, it means that there is short-circuit.
b)There is disconnection at Stator windings.
- opening cover of connector box, remove the star connection bridge. Control short-circuit or disconnection among windings.
c)One or more of bridge diodes are defective.
FAILURE: 12. FAILURES OF DIESEL MOTOR AND REPAIRS
6-Windings heat excessively.
Possible motor failures and their causes are stated below.
CAUSE: Starter motor revolves diesel slowly a)Generator is loaded over nominal.
• Battery has no charge • Contact of battery cables is poor • Starter motor is defective • Viscosity grade of lubricating oil is wrong
-operate at Nominal load. b)There may be short-circuit among windings.
-Perform short-circuit control among windings at connector box. Oil pressure is very low
• Viscosity grade of oil is wrong • There is not enough oil in the crankcase • Pressure indication is defective • Oil filter is defective
FAILURE: 7-There is undulation at output voltage of Generator. CAUSE: 47
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
• Oil pressure indication is defective Blue or white exhaust fume
• Viscosity grade of oil is wrong • Heater is defective • Diesel motor is cold • Valve adjustment out of order • Fuel advance adjustment out of order
Motor does not provide enough power
• Fuel pipe is clogged • Fuel filter is dirty • Air filter is dirty • There is air in Fuel system • Third class fuel • Exhaust pipe is clogged • Fuel leading pipe is defective • Governor is defective • Motor heat is high • Motor heat is low • Injections are defective or their adjustment is out of order • Fuel tank ventilation is clogged • Fuel advance adjustment out of order
Diesel motor Works hard or does not work
• Starter motor revolves diesel hard. • Fuel tank is empty • Fuel pipe is clogged • Fuel control solenoid is defective • Fuel filter is dirty • Heater does not function • Exhaust pipe is clogged • Third-class fuel • Fuel tank ventilation is clogged • Fuel leading pump is defective • Injections are defective or their adjustment is out of order • Oil sensor connection is defective
Motor functions irregularly
• Fuel pipe is clogged • Fuel governor is defective • Fuel filter is dirty • Fuel pump is defective • Air filter is dirty • There is air at fuel system
Oil pressure is very high
• Viscosity grade of oil is wrong 48
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
• Injections are defective or their adjustment is out of order • Fuel tank ventilation is clogged • Valve adjustment is out of order • Motor heat is very high • Heater system is defective • There is resistance in the action of Fuel governor
• Fuel filter is dirty • There is air at fuel system • Fuel pump defective • Motor heat is very low • Valve adjustment is wrong • Injections are defective or their adjustment is out of order • Heater is defective • Oil sensor or its connection is defective
Motor heat is very high
• Exhaust pipe is clogged • Cooling fan is damaged • Radiator core is dirty or pipe is clogged • Cooling system is insufficient • Air filter or pipe is clogged • Injections are defective or their adjustment is out of order • Heater system is defective • The oil level in the crankcase is low • Water to cool level is insufficient
There is knocking in the motor
• Valve adjustment is out of order • Injector is defective or its adjustment is out of order • There is failure at Fuel pump • Third-class fuel • Motor heat is very low • Heater system is defective Fuel consumption is very much
Crankcase pressure is high
• Air filter is dirty • Fuel is third-class • Exhaust pipe is clogged • Heater system is defective • Valve adjustments are wrong • Motor temperature is very low • Injections are defective or their adjustment is out of order
• Crankcase ventilation pipe is clogged • Valve adjustment out of order Ignition (in case of not working)
• Fuel pipe is clogged 49
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
Exhaust fume is black
• Air filter is dirty • Motor is overloaded • Fuel is third-class • Exhaust pipe is clogged • Motor heat is very low • Valve adjustment is out of order • Injection is defective or its adjustment is out of order Vibrating operation
• Fan is damaged • Fuel governor has difficulty in its movements • Injection is defective or its adjustment is out of order • Motor heat is very low Motor stops after functioning
• There is air at fuel system • Fuel filter is dirty • Air filter or suction system is clogged • Oil sensor or its connection is defective • Stop solenoid conservative bobbin is defective
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
13. PERIODIC MAINTENANCE INSTRUCTION
51
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
DEAR EMSA GENERATOR USER;
PLEASE NOTE FOLLOWING POINTS TO ENSURE THAT YOUR GENERATOR WILL NOT BE VOID OF GUARANTEE BEFORE ITS TIME, FUNCTION PROPERLY AND BE LONG-LIVED. 1. TRANSACTIONS PERFORMED WHEN GUARANTEE DOCUMENT OR INVOICE ARE NOT PRESENTED WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. 2. THE WARRANY IS VALID ONLY FOR SPARE PARTS AND THE PERIOD IS FOR 1 YEAR OR 1000 HOURS RUNNING TIME FROM THE DATE OF DISPATCH. THE WARRANTY IS INVALID IN CASE OF GENERATOR IS INTERFERED BY OTHER PERSON THAN EMSA AUTHORISED SERVICES FOR ANY REASONS. 3. CHECKS AND MAINTENANCE STATED ON THE PERIODIC MAINTENANCE CHART MUST BE PERFORMED ON TIME AND COMPLETELY. FAILURES RESULTING FROM NOT HAVING PERFORMED PERIODIC MAINTENANCE ARE NOT WITHIN THE SCOPE OF GUARANTEE. INSTALLATION OF THE GENERATOR MUST BE PERFORMED AS STATED IN THE MANUAL. IF NOT, PROBLEMS TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. 4. THE CUSTOMER WILL BE RESPONSIBLE FOR FAILURES RESULTING FROM DIRTY AND WATERY FUEL. 5. OIL SELECTION OF MOTOR SHOULD BE IN ACCORDANCE WITH THE ONE STATED IN THE MANUAL. OTHERWISE, FAILURES TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. 6. BATTERIES DO NOT REMAIN UNDER WARRANTY IN CASE OF BREAKING, EXCESSIVE ADDITION OF ACID, HARDENING DUE TO NOT CHARGING. 7. DO NOT START UP OR STOP DIESEL MOTOR WHEN GENERATOR IS UNDER LOAD IN MANUAL GENERATORS. STARTING AND STOPPING MUST BE PERFORMED AFTER LEAVING OF LOAD, WHEN GENERATOR IS IDLED. OTHERWISE, COMPRESSIONS MAY OCCUR IN THE VALVES. THIS CAUSES DAMAGES IN VOLTAGE REGULATOR, TRANSFORMER AND DIODES. THESE CONDITIONS ARE NOT UNDER WARRANTY. 8. OUR COMPANY IS NOT RESPONSIBLE FOR FAILURES RESULTING FROM OVER CURRENT, LOW AND HIGH VOLTAGE TO OCCUR IN THE NETWORK CONTACTOR USED IN AUTOMATIC GENERATORS. 52
DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL
NOTES
55
