Production instruction for the driver of a diesel power plant (diesel power plant). Instructions for labor protection when working at diesel and gasoline power plants Operation manual for diesel power plants

Trouble-free and trouble-free operation of the power plant is possible only under the condition of a clear and uninterrupted functioning of all its components and systems. Maintenance personnel must clearly understand the principle of operation of the installed equipment, control and signaling circuits, automation and control units, as well as design features, layout and interconnection of individual equipment elements. Only specialists who have studied and mastered the technical documentation for installed equipment, its material part, knowing the operating conditions of this equipment.

If a diesel power plant is served by two teams - electricians and diesel operators, then both teams, having perfectly studied the units and systems entrusted to them directly, should have an idea about the operation of all the equipment of the diesel power plant as a whole.

Persons servicing DES must pass a test of knowledge of the rules in a special commission technical operation electrical installations, safety and fire safety, operating instructions, technical minimum for equipment to be serviced and methods of first aid in case of accidents.

To obtain practical skills in maintenance and a more detailed acquaintance on the spot with the location and condition of the equipment, each employee servicing the diesel power plant must undergo an internship at the workplace lasting at least two weeks under the guidance of a more experienced employee; after that he is allowed to work independently. Persons servicing the diesel power plant are subject to periodic testing of knowledge of the rules of technical operation and safety. The listed requirements for the operating personnel make it possible to ensure reliable, safe and rational operation of the diesel power plant.

2. PREPARATION OF POWER PLANTS FOR OPERATION

Before start-up, the diesel power plant must be carefully checked and prepared for operation. It is necessary to inspect the diesel engine, generator, auxiliary units, panels and shields and eliminate the detected malfunctions. Using a 500 V megger, check the insulation resistance of the unit circuit with the switches on; resistance must be at least 0.5 MΩ.

If the insulation resistance of the generator and the rest of the circuit is below 0.5 MΩ, dust, wipe or dry exposed electrical insulating parts; if necessary, dry the generator. When preparing the diesel power plant for operation, it is necessary to check the degree of discharge of the batteries and correct the ignition systems. Starting a diesel engine with a starter when the batteries are discharged more than 50% is not allowed.

The service fuel tank must be filled with fuel and the fuel tank valve in the open position. The fuel level in the supply tank is controlled by the fuel level gauge. A fully filled service tank ensures continuous operation of the generating set for at least 4 hours.

It is necessary to make sure that there is no air in the fuel system, fill the service and additional oil tanks, and also fill the internal circuit of the cooling system with water (if any) and check the water circulation in the external circuit of the cooling system.

There should be no leaks in the fuel supply, lubrication and cooling systems of the diesel engine. If necessary, tighten the sealing nuts, clamps and clamps.

Before starting, check the tightness of all air cleaner connections and the air lock mechanism.

The position of the switches and switches on the panels, control panels of the generator and diesel automation must comply with the operating instructions for the DPP.

The mains generator circuit breaker must be open and the control circuit switch must be set to Manual Override or Auto Magic Start.

After carrying out these operations, the DPP electric unit is considered prepared for start-up and operation.

3. START-UP, OBSERVATION OF THE OPERATION OF POWER PLANTS AND THEIR SHUTDOWN

Starting and stopping the diesel power plant can be manual - from the local diesel control panel, remote - from the remote control remote control or automatic - without the intervention of maintenance personnel on the signal of automation when changing the control parameters in the network or on another unit.

Manual start and stop are made in accordance with the factory instructions. After starting and warming up the diesel engine at idle, its speed is gradually brought to the maximum. Then the generator is excited and the current frequency is set to 50 Hz using the frequency meter by changing the diesel engine speed. By turning the resistance knob of the voltage setting on the voltmeter, the rated voltage of the generator is set, after which the generator machine and the load to the generator are turned on. After start-up, the normal operation of the water and oil cooling systems is checked.

To stop the DES, turn off circuit breaker generator (remove the load), reduce the voltage on the generator and reduce the engine speed. The diesel engine runs at idle, followed by a slow decrease in speed until it stops completely.

Remote automatic start and stop are made from the remote control or control cabinet using control buttons. All operations for starting and stopping the generating set are carried out in a given technological sequence by the automation circuit.

In the event of a successful start, the signal lamp lights up Normal operation; if it occurs emergency mode, then it works alarm or protection and an automatic stop of the DPP occurs.

Automatic start and stop are carried out in a certain technological sequence without the intervention of personnel by the automation circuit.

The signal for automatic start is a change in the control parameters of the redundant electric unit: an unacceptable decrease or increase in voltage, an overload of the electric unit, an unacceptable decrease in the voltage of the industrial network.

The signal for automatic shutdown is a reduction in the total load of two parallel generating sets (main and standby) to 80% of the rated power or restoration of voltage in a controlled industrial network.

Automatic shutdown of the generating set occurs when emergency conditions occur and alarm and protection sensors are triggered. The inclusion of DPP generators for parallel operation is carried out in accordance with the recommendations.

Supervision of the operation of the diesel power plant in normal operating conditions.

During diesel operation it is necessary:

monitor the readings of the diesel operation control devices (oil and water temperature, oil pressure, etc.), the presence of coolant in the system, the oil supply to the diesel engine parts and the operation various sensors diesel;
replenish fuel tanks in time; pay attention to the presence of extraneous noise or knocks in the diesel engine;
in the absence of automation, monitor the engine speed and, if necessary, adjust it. When servicing the generator, you must: monitor the readings of ammeters, voltmeters, wattmeters. Exceeding the nominal values is unacceptable. Unsymmetrical loading up to. 25% of rated current and current overload not more than 10% for 1 hour;
control the temperature and noise of the bearings. The temperature of the bearings is controlled by touch by hand (or a thermometer) by the temperature of the covers in accessible places and should not exceed 80 ° C. The noise of the bearings should be heard through a special wooden rail. One end of the rail must be attached to the ear, and the other to the hub or other part of the end shield. If the bearings are in good condition, a uniform rumble is heard without knocks and shocks;
check the vibration of the generator by touch. If the vibration is greater than normal, it is measured with a vibrometer in the radial direction vertically and horizontally. The double vibration amplitude of the generator when working with a diesel engine, measured on the end shields, should not exceed 0.2 mm or the data given in the instructions for the generator;
adjust the voltage and frequency within the nominal values;
observe the readings of insulation monitoring devices, emergency and warning signals: if necessary, take measures to eliminate abnormal modes;
periodically monitor the operation of the brush apparatus of the exciter and slip rings of the rotor;
evenly distribute the load (in the absence of automation) between parallel generators;
periodically listen to the generator for the absence of knocks and extraneous noise;
in the event of a sudden disappearance of the readings of one of the stator or rotor devices, check with other devices whether this is the result of damage to the device itself, supply chains, etc.

If the device or the supply circuit is damaged, then, without changing the operating mode of the generator, it is necessary to take measures to eliminate the malfunction.

2. OPERATION OF STATIONS

3. OBSERVATION OF DPP OPERATION

4. SAFETY INSTRUCTIONS WHEN WORKING WITH DES

LITERATURE

1. PURPOSE AND CLASSIFICATION OF DIESEL POWER PLANTS

Along with the centralized method of power supply to consumers from the networks of power systems, in some cases it is necessary to provide for local sources of power supply. These include diesel power plants, which are also widely used as backup units that provide consumers with electrical energy during power outages in the event of accidents on the lines of the power system. For consumers with increased requirements for uninterrupted power supply, the installation of backup power sources is mandatory.

According to their purpose, diesel power plants and electric units are divided into stationary and mobile, and according to their design, they are built in temporary and permanent premises. Depending on the volume of automation, stations and electrical units can be 1,2 and 3rd degree of automation. They can be made with air, water-air or radiator, as well as water-water - double-circuit systems cooling.

Mobile diesel units are designated by the letters AD, stationary

ASD or DG, automated units are indicated by an additional letter A.

So, a mobile diesel generating set with a capacity of, for example, 30 kW three-phase alternating current voltage 230 V with air system cooling, the 1st degree of automation will have the designation AD-30-T / 230-A1V. The same unit in a stationary version of the 2nd degree of automation is designated ASD-30-T / 230-A2V. A non-automated stationary unit of the same capacity with a radiator cooling system is designated ASD-30-T / 230-R.

At diesel power plants, generators of the types SGD (synchronous generator, diesel), ESS (single series with self-excitation), EC (single series), MSD open and protected MSA with self-ventilation, etc. are used.

Mobile diesel power plants are made as complete electrical installations mounted on any vehicle and protected from atmospheric influences. Diesel generating sets are also made as complete units in the form of separate units, most often mounted on a common frame.

Stationary diesel electrical installations are designed for normal operation and generation of electricity of the required quality at an ambient temperature of +8 to +40 ° C, an altitude of not more than 1000 m above sea level and a relative humidity of up to 98% at +25 ° C. Mobile electrical installations generate electricity when the ambient temperature fluctuates from -50 to +50°C with the same humidity and installation above sea level at an altitude of up to 4000 m.

The main element of a diesel-electric installation (station or unit) is a diesel generator, consisting of a diesel engine, an electric generator, three-phase alternating current, cooling systems, lubrication, fuel supply and control panels.

Mobile power plants of the ESD type are equipped with AD (ASD) diesel units, and ESDA power plants are equipped with AD and ASDA units.

Units such as ASD, ASDA with a capacity of 30-100 kW are used as backup electrical installations. For them, power plants such as DES are also used. For stationary backup power plants of greater power (300-500 kW), diesel generating sets of AS, ASDA, DGA, etc. types are used. Such backup power plants are built indoors. They are located in the immediate vicinity of the reserved object or in the center of loads, for redundant transformer substations of consumers, taking into account the reservation, first of all, of the most responsible consumers of electricity.

2. OPERATION OF STATIONS

Trouble-free and trouble-free operation of the power plant is possible only under the condition of a clear and uninterrupted functioning of all its components and systems. Maintenance personnel must clearly understand the principle of operation of the installed equipment, control and signaling circuits, automation and control units, as well as design features, layout and interconnection of individual equipment elements. Only specialists who have studied and mastered the technical documentation for the installed equipment, its material part, and the operating conditions of this equipment may be allowed to service the DPP.

If DPP is served by two teams - electricians and diesel operators, then both teams, having perfectly studied the units and systems entrusted to them directly, should have an idea about the operation of all DPP equipment as a whole,

Persons serving diesel power plants must pass a special commission to test their knowledge of the rules for the technical operation of electrical installations, safety and fire safety, operating instructions, the technical minimum for equipment being serviced and methods of first aid in case of accidents.

In order to gain practical skills in maintenance and a more detailed acquaintance on the spot, each employee servicing the diesel power plant must undergo an on-the-job probation lasting at least two weeks under the guidance of a more experienced employee. After that, he is allowed to work independently. Persons serving DPP are subject to periodic testing of knowledge of the rules of technical operation and safety. The listed requirements for the operating personnel make it possible to ensure reliable, safe and rational operation of the diesel power plant.

2.1 Preparing power plants for operation

Before start-up, the diesel power plant must be carefully checked and prepared for operation. It is necessary to inspect the diesel engine, generator, auxiliary units, panels and shields and eliminate the detected malfunctions. Using a megohmmeter, check the insulation resistance of the unit circuit with the switches on; resistance must be at least 0.5 mΩ.

If the insulation resistance of the generator and the rest of the circuit is below 0.5 mΩ, clean the dust, wipe or dry the exposed electrical insulating parts; if necessary, dry the generator. When preparing the diesel power plant for operation, it is necessary to check the degree of discharge of the batteries and the serviceability of the ignition system. Starting a diesel engine with a starter when the battery is discharged more than 50% is not allowed.

The service fuel tank must be filled with fuel and the fuel tank valve in the "Open" position. The fuel level in the supply tank is controlled by the fuel level indicator. A fully filled service tank ensures continuous operation of the generating set for at least 4 hours.

There should be no leaks in the fuel supply, lubrication and cooling systems of the diesel engine. Tighten sealing nuts, clamps and clamps if necessary.

Before starting, check the tightness of all air cleaner connections and the air damper mechanism.

The position of the switches and switches on the panels, control panels of the generator and diesel automation must comply with the operating instructions for the DPP.

The mains generator circuit breaker must be turned off and the control circuit switch must be in the "Manual" or "Auto start" position.

After carrying out these operations, the DPP electric unit is considered prepared for start-up and operation.

2.2 Starting and stopping power plants

The start and stop of the diesel power plant can be manual - from the local diesel control panel, remote - from the remote control or automatic - without the intervention of maintenance personnel on the automation signal when changing the control parameters in the network or on another unit

Manual start and stop are made in accordance with the factory instructions. After starting and warming up the diesel engine at idle, its speed is gradually brought to the maximum. Then the generator is excited and the current frequency is set to 50 Hz using the frequency meter by changing the engine speed. By turning the resistance knob for setting the voltage, the voltmeter is set to the minimum voltage of the generator, after which the generator machine and the load to the generator are turned on. After start-up, the normal operation of the water and oil cooling systems is checked.

To stop the diesel power plant, turn off the automatic generator switch (unload), reduce the voltage on the generator and reduce the diesel engine speed. The diesel engine runs at idle, followed by a slow decrease in speed until it stops completely.

In the event of a successful start, the "Normal operation" signal lamp lights up. If an emergency mode occurs, then an alarm or protection is triggered and the DPP is automatically stopped.

Automatic start and stop are carried out in a certain technological sequence without the intervention of personnel by the automation circuit.

Operation manual for diesel generator AD-100/400 (DES) Zapadnokrymskaya substation

These instructions should be familiar to:

1. Engineer gr. Substation Zapadnokrymskaya

2. Duty dispatcher gr. Substation Zapadnokrymskaya

3. Duty electrician tr. Substation Zapadnokrymskaya.

Technical certificate.

Brand - AD - 100 - T / 400 1P No. 9276532.

Power -- 100kW.

Voltage - 0.4 kV.

Frequency -- 50Hz.

Engine type YaMZ - 238. No. 675295.

Generator type GS - 100. No. 84775.

Year of issue 1992.

1. Appointment.

1.2. DES is designed to operate in the following conditions:

Ambient temperature from -10 to + 550С.

Dust - with air dust content, no more than - 0.5 g / m3.

2. Technical data.

2.1. Designation DES - AD - 100 - T / 400.

2.2. The designation of the YaMZ-238 diesel engine.

2.3. The designation of the generator is GS-100.

2.4. The connection of the diesel engine with the generator is an elastic coupling.

2.5. DES start system - starter.

2.6. DPP nominal power - 100kW.

--\\-- --\\-- maximum for 2 hours 110 kW.

2.7. Kind of current - variable three-phase.

2.8. Frequency -50 Hz.

2.10. The current strength at Рnom is 180A.

2.11. Rotation frequency Рnom - 1500 rpm. At x / x 1545 rpm.

2.12. Specific fuel consumption - 175g/l. s./hour

2.13. Specific oil consumption - 0.38g/l. s./hour

2.14. Diesel oil pressure - 4 - 7 kgf / cm2.

The maximum temperature is 980C.

2.16. Coolant temperature 800 - 950C, maximum - 950C.

2.17. Permissible overload of the generator by 10% over the nominal for 1 hour.

2.18. The regulation system provides smooth voltage regulation.

2.19. The generator allows long-term operation with a symmetrical phase load up to 25% of the rated current. In this case, the unbalance factor of the line voltage does not exceed 10% of the nominal.

2.20. DES provides long-term operation at a load of at least 20% of the rated power.

3. Device, start-up and operation of DPP.

3.1. DES consists of: an engine with a cooling and control system, a generator with an excitation and control system, and all this is mounted on a frame.

3.2. Installed on the side of the trailer oil radiator, engine cooling radiator, engine, coupler, generator, generator control and excitation panel, fuel tank above the panel. On the left side is the engine control panel, the batteries are installed on the footboard. All DPP equipment is closed with an opening metal hood.

3.3. The engine is started by pressing the "STARTER" button, pre-set the engine speed below average, after starting, adjust according to the engine operation. Further speed adjustment by pressing the "engine speed control" button. Make sure that there is oil pressure in the engine system according to the instrument reading, warm up the engine to a temperature of 400C

3.4. Engine cooling system liquid, with forced circulation liquids.

The liquid in the radiator is cooled by forced circulation created by the engine pump.

The coolant temperature is controlled by a pointer mounted on the control panel.

The cooling system is designed to maintain the recommended thermal conditions.

3.5. Generator.

The electrical installation has a three-phase generator with a static excitation system. The generator serves as a source of electrical energy.

3.6. Remote Control.

The control panel includes equipment and devices that provide control and monitoring of the operation of the electric. installation. On the dashboard are: voltmeter, frequency meter, ammeter, engine control equipment, coolant temperature gauge, oil pressure gauge, battery current gauge, fuel level gauge in the tank, starter switch, engine speed control switch, generator excitation switch, voltage regulator potentiometer .

4. General instructions for use.

4.1. Persons who have been trained and trained to study the device and the operating instructions for the electrical installation are allowed to service the electrical installation.

Maintenance personnel for reliable and trouble-free operation of email. installation is necessary:

Firmly know the device and operating rules e-mail. installations,

Have a solid knowledge of the theoretical foundations of electrical engineering and mechanics to the extent necessary for the correct operation of the email. installation.

Monitor the technical condition of installation and timely maintenance.

Know and follow the safety regulations for the operation of a diesel generator.

Accurately and accurately maintain technical documentation.

Attention:

Before starting the diesel generator, it is necessary to check:

a) the presence of oil in the crankcase.

b) the presence of coolant or water in the cooling system.

c) Check the disconnected position AB - DS.

5. Indication of safety measures during operation.

5.1. When operating a diesel generator, the following safety measures must be observed:

a) rules for the installation of electrical installations (PUE).

b) TEESS Rules.

c) rules safe operation electrical installations (PBEE).

d) safety rules for servicing the battery, generator, internal combustion engine.

Persons with a safety group of at least III are allowed to service the diesel generator.

Keep unauthorized persons away while the diesel generator is in operation.

Monitor the serviceability and availability of fire extinguishing equipment and keep them always ready for use.

Do not use open flames or smoke when filling fuel and oil.

Fuel and oil are filled with special funnels.

Make sure that there are no leaks of oil and fuel (if leaks are detected, immediately eliminate them).

Make sure that during the operation of the diesel generator there are no flammable materials near the exhaust pipe (muffler)

Forbidden - during the operation of the diesel generator, carry out repairs, lubricate, etc.

Open the water radiator filler cap without gloves to avoid burns.

Maintenance personnel must have special training.

Know the rules for providing first aid to the victim in the event of an electric shock. electrocution, poisoning carbon monoxide, burns. Know how to provide first aid.

5.2. Electrical installation, diesel generator, operates in a network with isolated neutral.

To prevent maintenance personnel from getting under voltage, the diesel generator housing must be grounded.

Operation of an ungrounded electrical installation housing prohibited.

- insulation resistance must be at least 50 kOhm.

During the operation of the diesel generator, the following rules must be observed:

Do not touch during operation. installation to clamps and uninsulated current-carrying parts.

Before using protective equipment, check its serviceability.

Do not allow unauthorized persons to operate the electrical installation.

6. Preparation for operation of the diesel generator.

6.1. Check for fuel in the fuel tank. The fuel level is controlled by the “FUEL” indicator on the control panel (with the mass turned on).

Check the oil level in the sump and engine air filter, top up if necessary.

Refill the cooling system.

Connect the batteries to the circuit.

6.2. Preparation and inclusion in work (START).

Make sure there are no leaks: fuel, oil, water.

Check strength contact connections in an electrical circuit.

Check drive belt tension.

Check the grounding of the electrical installation.

Set the circuit breaker to the “OFF” position.

Turn off the "MASS" switch.

Set the RPM switch to the higher position and set the starting RPM.

Turn on the “STARTER” switch (the duration of continuous operation of the starter should not exceed 10 seconds. If after 10 seconds the engine does not start to work steadily, turn off the starter and after 1-2 minutes. Repeat the start. If after three attempts the engine does not start, you should find cause and correct).

Warm up the engine to a temperature of 40-50*C.

Set the “REVOLVE” switch to the “HIGH” position and after 4-5 seconds. excite the generator by turning it on for 2-5 seconds. The “EXCIT” switch, the voltmeter on the console should show voltage.

Set the frequency to 52-54 Hz with the “REVOLUTION” switch.

Using the “VOLTAGE SETTING” resistor, check and install a voltmeter with a measurement limit of 500-400-430 V.

6.3. The operation of the diesel generator in idle mode and in load mode.

When the diesel generator is idling, check:

Indications of the index of water temperature, oil pressure.

Follow the indications of control and measuring devices.

Maintain coolant temperature within 75-980C.

Avoid leakage of fuel, oil and coolant.

Monitor the operation of the brushes on the slip rings of the generator. All abnormalities noticed during the operation of the diesel generator must be recorded in the shift magazine and notify the substation management.

6.4. The diesel generator must be stopped immediately:

With an unacceptable decrease in oil pressure.

With an unacceptable increase in the temperature of the coolant.

When there are sharp unusual knocks.

With an unacceptable increase in the frequency of rotation of the engine shaft (spacing).

6.5. Stop diesel generator.

Disable auto-I.

Set the engine to starting speed and run for at least 5 minutes.

Stop the engine with the “STOP” device.

Turn off the mass switch.

6.6. The order and maintenance of the diesel generator after completion of work.

Check if the switches are turned off and if the cable network of consumers is disconnected.

Determine the defects noticed during the work.

Wipe the engine, generator with a dry rag, remove smudges of oil, coolant, fuel.

Inspect the main mount constituent parts electrical installations and eliminate the noticed defects.

It is allowed to leave the cooling system charged when filling with low-freezing liquid.

6.7. If malfunctions are detected during the operation of the electrical installation, it is necessary first of all to establish whether there are any external causes causing malfunctions, and to check for wire breaks and broken contacts in the consumer circuit. Switching devices and el. Measuring instruments are not subject to repair under operating conditions.

Main possible faults engine, generator, trailer and other organs and ways to eliminate them are detailed in operational documentation on them.

7. Maintenance.

To ensure normal operation, it is necessary to carry out maintenance maintenance.

Maintenance ensures that the DPP is maintained in constant readiness for operation. Compliance with the terms and procedure for maintenance is a prerequisite for long-term operation of diesel power plants.

Maintenance is carried out by maintenance and repair personnel of the substation.

When operating a diesel power plant, for readiness at any time of the day or night, it is necessary:

Run DES weekly for 10 minutes. in summer time for 30 min. in winter time.

If a malfunction is detected, it is necessary to eliminate it without waiting for the next maintenance.

The first maintenance is carried out every 125 hours of operation.

The second maintenance is carried out every 500 hours of operation.

Defects found during the testing process should be repaired immediately.

The scope of work performed during TO-1 and TO-2 is given in the operational documentation.

Once a year, check the accuracy of electrical measuring instruments.

Once a year, carry out an audit of circuit breakers, cable terminal connections.

8. Engine specification.

Engine type YaMZ -238.

Number of cylinders --8.

Total displacement -- 14.86

Rated power l. with. -- 240.

Rated RPM --1500.

The capacity of the lubrication system is 32l.

Capacity of the cooling system (without radiator) --30l.

The firing order of the cylinders is 1-5-4-2-6-3-7-8.

Starter type --ST-103.

Battery capacity - 165 a / h.

9. Safety measures during operation.

During the operation of the electrical installation, the following must be carried out:

Rules for the installation of electrical installations (PUE).

TEESS Rules.

PB RULES in companies, enterprises in organizations of the energy industry of Ukraine NAPB V.01.034-2005/111.

When operating a DPP, the following rules must be observed:

Persons with a qualification of at least 3gr. on electrical safety.

During the operation of the diesel power plant, unauthorized persons are not allowed.

Maintain fire extinguishers and keep them in good condition.

When refueling a DPP with fuel or oil, it is forbidden to use open fire and smoke.

Make sure there are no fuel or oil leaks.

It is forbidden to lubricate, clean or repair the unit during operation of the diesel power plant.

Open the radiator cap while the diesel power plant is running.

Fuel refilling should be carried out after shutdown and disconnection from the electrical network of the diesel power plant using a funnel for filling fuel.

Service personnel must:

Have special training to ensure the correct and trouble-free operation of the diesel power plant.

Know how to provide first aid to an injured person.

Appendix 1. to the instruction manual for DPP

Actions of operational personnel in case of full repayment of the Zapadnokrymskaya PS

1. Report to DD SMES about the situation at the substation.

2. Check the position of the introductory circuit breakers of the main switchboard SCSN-0.4 kV from TSN-1 and TSN-2:

AV input from TSN-1 - included.

AV input from TSN-2 - enabled.

SV - 0.4 kV - disabled, ATS in the position - "disabled".

3. SCHSN-0.4 kV P 8, 9, 10, 11, 12 AV - disabled.

4. TSN-2 cabinet 0.4 kV disconnect AV-1 and AV-2. AB-2 to transfer to the control position.

5. Switch AV-3 to the “work” position and turn it on, while AV DES must be in the “off” position.

6. Start up the diesel power plant in accordance with P - 6.2; 6.3. this manual.

7. Raise the DES speed by pressing the "Excitation" button for 2 seconds. and excite the generator.

8. Raise the voltage to 0.3 kV using a rheostat.

9. Set the generator speed to 52-54Hz.

10. Adjust the voltage 0.4 - 0.44 kV.

11. Turn on the AV DES on the DES shield.

12. Main switchboard SCCHSN-0.4 kV P-7 check the presence of voltage on S-2 0.4 kV.

13. SCHSN-0.4 kV P-11 turn on AV-1 VAZP-2, increase the voltage of AB 220V to 225V.

14. If necessary, turn on consumers from S-2 0.4 kV.

15. Report to DD SMES on the operations performed.

16. Monitor the operation of the diesel power plant and the voltage on the 0.4 kV C-2 buses.

17. When voltage is applied to S-1 0.4 kV DD PS:

Disables VAZP-2 P 11 AV-1.

Includes VAZV -1 P 3 AB-10.

Disconnects included AB from C-2 0.4kV.

Turns off the AV DPP and leads to the shutdown of the DPP in accordance with P 6.5 of this instruction.

Turns off AV-3, puts it in the "repair" position

AB-2 translates to the "work" position.

Includes AV-1 and AV-2 TSN-2 0.4kV. to work.

18. In the absence of voltage from F No. 8 "Kutur", disconnect the AV input from TSN-2 to SCHSN-0.4 kV P-7. Turn on SV-0.4kV P-6.

19. When voltage is applied from F No. 8 "Kutur", restore the normal SCHSN-0.4 kV circuit. substations.

1. General part

1.1. This manual has been developed on the basis of:

 "Technical description of power plant ESD-200-30-T/400M ODK.140.753";

 "Instruction for operation and storage of power plant ESD-200-30-T/400M ODK140.130";

 "Intersectoral rules on labor protection (safety rules) for the operation of electrical installations POT RM-016-2001 (RD 153-34.0-03.150-00)";

 "Rules for the technical operation of power plants and networks of the Russian Federation (UDK 621.311.004.24)".

1.2. This instruction defines the main provisions for the operation of the ESD-200-30-T / 400M diesel power plant (hereinafter DES - 200). More detailed information is contained in the "Instructions for the operation and storage of the ESD-200-30-T/400M power plant" and the factory instructions for the ESD-200-30-T/400M power units.

1.3. Diesel DES power plant- 200 installed at the substation is intended for backup power supply for auxiliary needs of 0.4 kV substation with voltage of 400 V, frequency of 50 Hz, in a stationary position, in case of complete loss of power supply to TSN - 1.2 via 6 kV cable lines.

1.4. Only persons who have undergone special training to ensure the correct operation of the DES - 200 are allowed to service the DES - 200 in accordance with this manual, "Instructions for the operation and storage of the power plant ESD-200-30-T / 400M" and the current "Intersectoral rules on labor protection (safety rules) for the operation of electrical installations POT RM-016-2001 (RD 153-34.0-03.150-00)" .

2. The procedure for admission to inspection, repair and testing of equipment DES - 200

2.1. A single inspection of the electrical equipment of DPP - 200 substations can be performed by an employee with a group of at least 3, from among the operational personnel serving this electrical installation during working hours or on duty, or an employee from administrative and technical personnel with a group of at least 4 and the right to sole inspection on the basis of a written order of the head of the organization.

2.2. Admission to repair work on the equipment of the DPP - 200, verification of automation and measurement equipment, testing of the DPP equipment - is carried out by the operating personnel of the SUBSTATION.

2.3. Tests of electrical equipment of DPP - 200 are carried out by SIZP personnel. When testing substation equipment, busbars (busbars after testing) of the equipment are carried out by the repair personnel of the SPS. This personnel may be included in the SIZP team.

2.4. Decommissioning of DPP-200 equipment from work for repair, testing of automation and measurement equipment, testing is carried out according to applications submitted to the operational dispatch service.

2.5. The procedure for shutting down equipment, issuing a permit for preparing a workplace, and paying off a permit is regulated by the "Instructions for organizing the withdrawal for repair and commissioning after repair of equipment".

2.6. Works on auxiliary equipment DES - 200, which do not affect the readiness to start the station into operation, can be carried out during the work shift with the permission of the ODO dispatcher.

3. The order of installation for operation and clotting DES-200

3.1. When locating DES-200 on site, it is necessary to be guided by the convenience of its maintenance. For the convenience of servicing the product, there should be a fairly free passage around it, and the site where the DES-200 is supposed to be installed should be planned and cleared of foreign objects. In addition to DES-200, an access road must be provided for the access of a fuel tanker.

3.2. Deployment of DES-200 must be carried out in the following order:

3.2.1. Install DES-200 on the site and brake using the trailer's hand brake;

3.2.2. Clean the trailer chassis and body from dirt and dust;

3.2.3. Remove the jack handles, stretch marks and wooden spacers from the box with spare parts and accessories for the trailer;

3.2.4. Remove the locking pins securing the jacks in the stowed position;

3.2.5. Lower the jacks and fix them in a vertical position with stretch marks;

3.2.6. Place wooden spacers, install the handles in the jacks and, by rotating the latter, lower the movable part of the jack so that its shoe presses the wooden spacer to the ground;

3.2.7. Raise the DES-200 to a position where the trailer wheels are free from load, and then, by adjusting the jacks, set the body to a horizontal position. When lifting, you must be guided by the following provisions:

 lifting of DES-200 should be carried out evenly with the transition from one jack to another or simultaneously by all jacks;

 DES-200 lifting should be done by uniform rotation of the jack handle, while the applied force on the handle should be no more than 20 kg.

 in the event that the braking of the lift occurs, which will cause a sharp increase in the applied force on the handle, the lift must be stopped.

 for visual control of lifting, an annular groove is made on the movable part of the jack (pipe), which is painted red. The moment it leaves the jack body signals the need to stop lifting.

 upon receiving a signal to stop lifting, it is necessary to raise the jack, put one or two additional pads under its shoe, then the lifting can be continued.

 After installing the DES-200 on the jacks, it is necessary to release the trailer.

3.2.8. Open hatches and doors and inspect the trailer components (wheels, drawbar, brake system), fastening the body to the trailer chassis, fastening units, switch cabinet, as well as fastening diesel generator units to the frames of the units. All identified defects must be corrected.

3.2.9. Install the muffler of the AD-30 unit in place (on the roof of the body).

3.2.10. If DES-200 was mothballed, re-mothball it.

3.2.11. If it is necessary to remove exhaust gases away from the DPP-200, you need to install a portable ladder on the roof, remove the nozzle from the muffler of the AD-30 unit, and attach exhaust hoses in its place. Attach exhaust hoses to the exhaust of the PZhD heater, if necessary. (Pre-exhaust sleeves must be connected two sleeves together). Attach exhaust hoses to the mufflers of the AD-200 unit (one to each muffler).

3.2.12. Expand cable network.

3.2.13. Install protective grounding using the grounding device attached to the DES-200 or existing grounding devices at the station installation site. The ground loop is connected to the ground studs on the DES-200 "EARTH" terminal blocks.

The connection diagram of the ground loop - "protective ground" and the method of installing the loop are indicated in the technical description for the DES-200.

Before connecting the ground wires to the ground studs of the DES-200 terminal blocks, make sure that there is no paint, grease or corrosion on the wire lugs and on the studs.

3.3. When closing the DES-200, the following work must be performed:

3.3.1. Remove the exhaust hoses, disconnect and secure them in the stowed position to the trailer chassis and body.

3.3.2. Install the nozzle on the silencer AD-30.

3.3.3. Install the portable ladder in the stowed position and secure to the body.

3.3.4. Disconnect the earth cables and stow them in a box under the body.

3.3.5. Jack up, DES-200. Raise and secure all jacks in the profitable positions, and clean the gaskets and handles from dirt and put them in a box.

3.3.6. Close all boxes, hatches and doors DES-200.

3.3.7. Examine the DES-200 from the outside in order to check the reliability of fastening of all accessories.

3.3.8. Inspect the DES-200 site and clean it of debris and other traces of stay.

4. Preparation for operation of DES - 200.

4.1. When carrying out preparatory work, it must be remembered that the more carefully the station is prepared for work, the sooner it will be possible to put it into operation and the more reliably it will work.

4.2. Before starting the testing and preparatory work, all switches, switches must be set to the "OFF" position.

4.3. Power and control cables may only be connected to the terminal blocks in the absence of voltage. In this case, the signal lights installed on the panels of the terminal blocks should not light up.

4.4. Check the reliability of grounding DES-200, it must be performed by two conductors.

4.5. Check the condition of the DES-200 electrical installation, the condition of the insulation and the good condition of the contact connections.

4.6. Check the condition of the brushes and brush holders on all generators. If wear is found, they must be replaced.

4.7. Check the serviceability of fuses, switches, switches and other elements installed on the panel of the distribution cabinet and blocks with equipment. Check to make an external inspection, as well as for functioning (switching on, turning off, etc.).

4.8. Measure the resistance of the electrical insulation of the electrical installation of the DES elements - 200 with a megohmmeter at 500V. The insulation resistance must be at least 500 kΩ.

4.9. Check the condition of the batteries and prepare them for work:

 check the electrolyte density in all batteries with an acid hydrometer (1.26 ÷ 1.28 g/cm3);

 check the electrolyte level and, if necessary, top up with distilled water so that the electrolyte level is 8-10 mm higher than the safety shield.

4.10. Check the DES-200 body lighting.

4.11. To plug power cables and control cables to the product, after checking the condition of the cable connectors and clamps. When connecting cables, strictly follow the markings on each cable and on the plug connectors and panels of the VK-1, VK-2 terminal blocks.

4.12. Check the presence of oil and coolant in the engine systems of the AD-200 and AD-30 units, as well as the presence of fuel in the fuel tanks. If necessary, refuel DES - 200 with fuel and oil.

4.13. Check for leaks in water, oil and fuel lines.

4.14. Open the air release hatches from the generator of the AD-200 unit, after lowering the spare wheel by 300-400 mm under the AD-200 air duct (to prevent rubber damage).

4.15. Open the hatches located opposite the radiators of the 1D12V-300 and YaAZ-M204G engines, as well as the hatches intended for air intake.

4.16. Put a rubber mat on the floor of the body in the operator's compartment.

4.17. Set all automatic switches, switches and switches to the off position, except for battery switches B6 on the AD-200 unit and B7 on the AD-30 unit.

4.18. Set the taps on tanks 1 and 2 to the position that provides fuel supply to the AD-200 and AD-30 units.

4.19. Connect the remote control (RC) through the SHRZ, SHR4 connectors

5. Work DES - 200

5.1. General provisions

5.1.1. DES - 200 installed at the substation can operate in the following modes:

5.1.1.1. Normal mode - with a normal power supply scheme for substation auxiliary consumers, DPP-200 auxiliary consumers are supplied from SCHSN-0.4 kV.

5.1.1.2. The main operating mode - the substation's own needs consumers and DPP - 200 own needs consumers are supplied from the AD-200 unit. In this mode, one of the compressors is allowed to start.

5.1.1.3. An additional operating mode - the substation's own needs consumers and DPP - 200's own needs consumers are supplied from the AD-30 unit. In this mode, it is not allowed to turn on the consumers of the compressor unit.

5.1.2. DES - 200 is connected to the 0.4 kV auxiliary switchboard (hereinafter referred to as SCHSN-0.4) of the substation through KL-0.4. One side of KL-0.4 is connected to the "NETWORK" terminals on the terminal panel PZ1 DES - 200, the other side is connected to the automatic switch 7 "Diesel generator" in the panel 27 SCHSN-0.4.

5.1.3. It is the responsibility of the operating personnel of the substation to start the DES - 200 units, turn on and off the current sources and consumers of electricity, make all the necessary switching using the switching equipment installed in the switch cabinet and control panels, and also monitor the parameters of the distributed energy.

5.2. Starting and stopping the AD-200 unit

5.2.1. Starting the engine of the AD-200 unit at an ambient temperature above +5 0С is carried out without the use of heating devices.

5.2.2. The diesel control panel installed on the AD-200 unit contains all the equipment necessary to start the engine and control devices for the condition of a running diesel engine: water and oil thermometers, oil pressure gauge, tachometer, voltammeter, etc.

5.2.3. Start the AD-200 unit with a starter.

5.2.4. Starting the engine with a starter can be done in the following three ways:

 start from the diesel control panel (local control);

 start from the remote control (hereinafter referred to as RC) manually (remote manual control);

 start from remote control automatically (automatic remote control).

5.2.5. Starting the engine with a starter, from the local diesel control panel of the AD-200 unit

5.2.5.1. Open the disconnect valves at the fuel tanks to supply fuel to AD-200.

5.2.5.2. Turn on the battery switch B6, mounted on the AD-200 frame, and turn on the switch B1 on the diesel shield.

5.2.5.3. Turn on the switch of the electric oil pumping unit "PUMP" and create an oil pressure in the main line of at least 2 kg/cm2.

5.2.5.4. Turn on the "STARTER" switch on the engine instrument panel and allow the engine crankshaft to turn a few revolutions, after which turn the fuel supply handle clockwise.

5.2.5.5. As soon as the engine starts to run, immediately turn off the "STARTER" switch and set a steady speed of 600-800 rpm.

5.2.5.6. It is allowed to turn on the starter switch for no more than 5-6 seconds. After each start attempt, you must take a break of 15-20 seconds.

5.2.5.7. After starting, before turning on the load, the engine must be warmed up at idle at 600-800 rpm. With a gradual transition to 1200-1300 rpm until the temperature of the coolant and oil reaches 30 0C, when the specified temperature is reached, increase the engine speed to 1545 rpm. In this case, the oil pressure should be in the range of 6-10.5 kg / cm2.

5.2.6. Stopping the AD-200 unit with local control

5.2.6.1. Disconnect the generator from the busbars of the station by moving the handle of the automatic switch AB1 "GENERATOR 200 kW" in the distribution cabinet (hereinafter referred to as RSH) to the OFF position.

5.2.6.2. By turning the fuel supply knob counterclockwise, reduce engine speed to 600-800 rpm.

5.2.6.3. The engine should run at low speed until the temperature of the coolant drops to +60 0С (if it has risen above +60 0С by this time). Only then can the engine be stopped. When stopping, the lamp LS1 "GENERATOR 200 kW" should go out.

5.2.7. Starting the engine of the AD-200 unit from the remote control manually (manual control)

5.2.7.1. The remote control is attached to the RSh from above, in the operator's office of the DES - 200.

5.2.7.2. Install switch B5 - "VOLTAGE REGULATION." on the RSH panel to the "DIST" position.

5.2.7.3. Open the disconnect valves at the fuel tanks to supply fuel to AD-200.

5.2.7.4. Turn on the battery switch B6, mounted on the AD-200 frame, and turn on the switch B1 on the diesel shield.

5.2.7.5. Set the type of operation switch P1 on the remote control to the "MANUAL" position.

5.2.7.6. Press the KU1 "START" button on the remote control. At the same time, the white lamp LN1 "CHECKING THE FUEL RAIL" should light up.

5.2.7.7. After the lamp LN1 goes out, press the button KU3 "BLOWING" and keep it on until the pressure in the oil line reaches 2 kg / cm2.

5.2.7.8. Press the KU4 "STARTER" button. The duration of the starter is no more than 5-6 seconds. Release the starter button immediately after starting the diesel engine. After starting the engine, the lamp LN2 "LOW TEMPERATURE" should light up.

5.2.7.9. If, after pressing the "STARTER" button, the engine does not start to work, it is recommended to make the next start attempt no earlier than after 40-50 seconds. It is recommended not to make more than four consecutive starts, and if after that the engine does not start, measures should be taken to eliminate the causes preventing starting.

5.2.7.10. Warm up the engine until the coolant temperature reaches +45 0C, while the LN2 "LOW TEMPERATURE" lamp goes out.

5.2.7.11. Bring the engine speed to 1545 rpm by pressing the button KU5 "MORE".

5.2.8. Starting the engine of the AD-200 unit from the remote control automatically (automatic control)

5.2.8.1. Install switch B5 - "VOLTAGE REGULATION." on the RSH panel to the "DIST" position.

5.2.8.2. Open the disconnect valves at the fuel tanks to supply fuel to AD-200.

5.2.8.3. Turn on the battery switch B6, mounted on the frame AD - 200, and turn on the switch B1 on the diesel shield.

5.2.8.4. Set the switch for the type of work P1 to the "AUTOMATIC" position, while the white lamp LN6 "AUTOMATIC" lights up.

5.2.8.5. Press the KU1 "START" button on the remote control. In this case, the white lamp LN1 "FUEL RAIL CONTROL" should light up and go out after a while. The engine should automatically start and reach 800-1200 rpm.

5.2.8.6. After starting the engine, the lamp LN2 "LOW TEMPERATURE" should light up.

5.2.8.7. When the coolant temperature reaches +45 0C, the "LOW TEMPERATURE" lamp will go out, the engine automatically increases the speed to the nominal speed (1545 rpm).

5.2.8.8. ATTENTION! If it is necessary to take an emergency load immediately after starting without warming up, bring the AD - 200 unit to nominal speed using the KU5 "MORE" button on the remote control, with the P1 switch position "MANUAL" with its subsequent transfer to the "AUTOMATIC" position.

3.1. general information and identification of generators

The diesel generator is designed as an integral device to provide excellent and reliable operation. The main elements are shown in the block diagram of a typical generator set, although there are several differences in the main structure for different models. This section describes the main elements of the generating set, more detailed descriptions of the characteristics are presented in the following sections.

Each generator has a nameplate affixed to the alternator housing (hereinafter referred to as the generator). The information on the nameplate is used to identify the generator model and its performance, including the model number, serial number, output voltage, phase, frequency and power rating (output power is in kVA or kW). The information is also repeated in the drawings attached to the documentation. The serial number is unique for each installation. When purchasing spare parts or when carrying out maintenance and repair services, the serial number of the unit must be given.

3.2. diesel engine

The diesel engine is the source of power in the genset and has the following features: specially designed for the genset, safe and uniform operation, industrial type, 4-stroke or 2-stroke compression ignition, a set of accessories for stable power supply. Options include: cylinder air filter, turbocharger, mechanical or electric regulator speed, providing precise control of the rotation of the generator.

3.3. Engine power supply system

Depending on the model, the power supply systems have a voltage of 12V DC or 24V DC, and include: a starter, a charging generator, batteries and a battery holder. For large generator sets, batteries and battery holders can be installed separately from the generator set. Typically, generator sets are equipped with one or two lead-acid batteries, which are described in detail in the tenth section. this manual. At the request of the customer, the engine can be equipped with other types of batteries.

3.4. Cooling system

The engine cooling system includes one radiator, one fan. The alternator is equipped with an additional fan to cool its parts. The air flow first passes the generator, then the engine and radiator.

3.5. Alternator

Output power comes from a single brushless, self-excited alternator with built-in voltage regulator. The generator has a waterproof housing with a protective coating and a top-mounted control system.

3.6. Fuel tank and platform

The engine and alternator are mounted on a heavy metal platform. For small generator sets, a fuel tank is installed in the platform, containing, when completely filled, fuel for 8 hours of operation. If the platform does not have a fuel tank, a separate fuel tank is offered.

3.7. dampers

The generator is mounted on dampers to soften the shocks transmitted to the base during start-up. The dampers are installed between the engine/generator stands and the platform. However, for large generator sets, the engine and generator are fixed to the platform and the dampers are offered to the customer for customer installation.

3.8. Silencer and exhaust system

The installation is completed with a silencer and an exhaust system in a disassembled state. The system reduces noise and removes exhaust gases to the outside.

3.9. Control system (specific features)

There are several types of control systems for different generator sets. Each unit has one system to control the operation and provide protection against breakdown in case of improper operation. The ninth section of the documentation provides additional information with markings and signals for various control systems.

3.10. Output air switch

To protect the generator set, a circuit breaker is installed in the auxiliary switch box, according to the power of the set. In some cases, the switch is placed together with an automatic shutdown system or control panel.

Structural diagram of a standard generator set

diesel engine
Damper
Control Panel
Connector
Platform

Installation, movement, transportation and storage

4.1 Basic principles

In the event that the dimensions and the corresponding control system or power system are agreed, a plan for the installation of a diesel generator can be developed. This section discusses the important elements for a safe and efficient installation. To receive additional information see installation instructions.

It is more convenient to mount and move generating sets with an external casing. Our company produces 2 models of generator sets with an external casing. One model with a closed top-mounted fixed-type or fixed-type sound-absorbing enclosure. Another model with a container-like body (can accommodate a person), stationary type or stationary type with sound absorption.

Casings are mounted for convenient transportation and installation, as well as protection of parts of the diesel generator from access by unauthorized persons.

Attention!

Before locking the cabinet door, check that there are no people inside.

4.3 Moving the generating set

The platform of the generating set is specially designed for easy moving of the set. Mistakes in handling can cause serious damage to parts of the generating set.

Raise or lower the unit with a forklift, or gently pull or push the platform. If the generator set is pushed, lay wooden planks between the fork of the loader and the frame to prevent frame breakage and redistribution of weight in the places where the frame is engaged by the loader. If it is necessary to move the generator frequently, oil sliding channels with grooves for the fork of the loader, as well as a suspension can be mounted on the installation frame. For smaller models, the platform has slots for a forklift.

Attention!

Do not use engine or generator eyebolts to lift the unit.

Check the condition of the hanger, the bracket and the allowable weight of the hanger.

Keep your distance when lifting the unit.

One single point hanger is installed to lift the generator set and one standard crane is required.

If the generating set is being lifted, check the lifting points, check that the connection is tight, that there are no cracks in the metal and that the connections are tight, etc. The lifting point with the set protection beam is at the center of mass (closer to the generator) of the whole generating set, and in this case a direct lifting can be used. When lifting the generator set off the ground, a steel cable must be used to prevent the set from swaying or rotating. Do not lift the generator set in strong winds. The generator set must be installed on a flat surface that can support its weight.

This lifting method is only used for installation lifting. If it is necessary to frequently lift the generator set, single-point lifting equipment should be installed. If the generator set is lifted by helicopter, a lifting ring is required.

4.4 Place of installation

It is very important to choose the right place for the generator set. Key factors to consider:

Good ventilation.
Protecting parts from rain, snow, hail, flooding, direct sunlight, low temperatures and overheating.
The equipment will not be exposed to polluted air containing earth dust, metal dust, wood chips, soot, smoke, steam, engine smog or other contaminants.
The machine is designed to be protected from falling trees or poles or other objects thrown from Vehicle and cranes.
There is enough space around the machine for cooling and maintenance: 1 meter around the machine and two meters from the top of the machine.
Make sure the room has an entrance large enough to bring in the generating set. Air must be easily drawn in and out.
There is protection from access by random persons.

If the generator needs to be installed outdoors, it must be equipped with an all-weather outer casing or a container-type casing, which is very useful when placing the generator set indoors and temporarily outdoors.

4.5 Platform and dampers

Before the generator set is shipped from the factory, the alternator and engine must be properly mounted on a rigid platform so that when the set comes into assembled, it is enough just to fix the generator set with bolts on a solid base.

4.5.1. Base: The best base for installation is a block of reinforced concrete. The base must provide rigid support for the generating set to prevent rolling and impact. Standard concrete block with a thickness of 150-200 mm with an area not less than the area of the installation platform. The ground under the unit must support the weight of the unit and the installation. (If the generator is installed above ground, the building structure must support the weight of the machine, fuel tank, accessories, etc.) The building must comply with building codes. If the ground is damp (as in a broiler house), the base should be above ground level to secure electrical connections, maintenance, and reduce platform metal corrosion.

4.5.2 Damper: dampers are installed between the engine/generator legs and the platform to reduce generator set vibrations transmitted to the building. The platform is attached directly to the base block. For large generator sets, the motor/alternator is rigidly mounted on the platform with additional dampers for customer installation between the platform and the base. In any case, the diesel generator must be rigidly fixed to the base (with or without dampers) to prevent movement.

External connections to the generator set must also be vibration damped, such as flexible fuel lines, flexible vent pipes, flexible exhaust gas connection, soft cable ducts, holders and connections, etc.

4.6 Engine air supply

The air entering the engine must be clean and cool. Usually, an air filter is installed to filter the air.

Sometimes the air is supplied from another location or room, as the air around the generator set may not be usable due to dust or temperature. Do not move the filter to another location if doing so could introduce dirt into the engine. If necessary, use manufacturer-approved air cleaning equipment, otherwise engine performance will be adversely affected.

4.7 Cooling and ventilation

The engine, alternator and fan generate heat, high temperatures impair the efficiency of the alternator. Therefore, it is necessary to take measures to cool the engine and generator. The correct direction of air flow is from the front end of the engine. It passes through the engine radiator and is discharged to the outside through an attached ventilation pipe. If there is no air outlet, then the hot air dispersed by the fan will return along a short path to the radiator, reducing the cooling efficiency.

The duct inlet and outlet must be large enough to allow free air flow. The area of the openings should be 1.5 times the area of the radiator.

Blinds must be installed at the inlet and outlet of the air duct to protect the diesel generator from bad weather conditions. Blinds must be fixed or adjustable. AT cold weather, if the generator is not working, it is necessary to close the blinds, keeping the heat in the room, which is good for the battery. For generator sets with auto start, the shutters should open automatically when the set is started. For a cooling and heat dissipation system without a heatsink, the heat generated by the generator set must be dissipated to the outside.

4.8 Exhaust

The removal of exhaust gases allows you to remove harmful smoke, smog, smell and reduce noise in the room. A suitable muffler, matched to the exhaust line, can be installed both inside and outside.

Attention!

All generator sets installed indoors must use sealed exhaust pipes to allow gases to be vented to the outside, and the installation of the exhaust pipes must comply with codes and standards.

Check that the hot exhaust system is away from flammable objects.

Check that exhaust fumes do not harm others.

During the development of an exhaust gas exhaust system, it is necessary to take into account the fact that the back pressure should be kept to a minimum value, because it greatly reduces the efficiency and service life of the engine and increases fuel consumption. Exhaust pipes should be kept as short as possible to reduce back pressure, in the case of a bend, the diameter of the bend should be at least 1.5 times the inner diameter of the pipe, and if the length of the exhaust system exceeds 3 meters, manufacturer approval is required.

Exhaust standards:

A flexible connection must be used to connect the exhaust pipe and the engine exhaust port. A flexible connection is needed to reduce vibrations transmitted to the exhaust system and the building. It also makes it possible to compensate for displacements due to thermal expansion of exhaust pipes and devices.
Be careful not to damage the exhaust pipes when installing the pipes and muffler.
The parts of the exhaust system passing through the room must be thermally insulated to reduce heat and noise. Pipes and muffler should be located away from flammable substances both inside and outside the room.
Long pipes should be angled with a drain cock installed at the lowest point to drain water and prevent it from entering the engine or muffler.
When passing a pipe through a wall, it is necessary to install a jacket that absorbs vibrations and protects flammable materials from the heated pipe, and also allows to compensate for the thermal expansion of the room and the heated pipe.
The end of the pipe that goes out into horizontal position must have a 60-degree cut and must be equipped with a canopy when installed vertically to prevent rain and snow from entering the exhaust system.
The exhaust system pipe must not be combined with pipes from other generators or pipes from a stove or boiler.

4.9 Fuel

The fuel system must have a constant supply of clean fuel for the engine. A fuel system installation typically includes one service tank, a large fuel tank, and a pump with related equipment.

Installation of an additional fuel tank for a stationary generator set must comply with standards and regulations.

Do not smoke, keep fire and sparks away from fuel. Fuel and oil vapors may explode if exposed to fire.

4.9.1 Service tank: the service tank directly feeds the engine with fuel, therefore it is installed in the generator room. For small generator sets, a metal or rubber permanent tank is mounted on a platform with a fuel line connected to the diesel engine. On a full tank, the generator set can run for 8 hours. With very large fuel tanks, the generator set can run up to 24 hours.

4.9.2 Large fuel tank: to increase the duration of the generator set without a constant supply of fuel, it is necessary to install an additional large fuel tank.

Usually large fuel tanks are installed outside for easy refueling, cleaning and checking, in cold areas the tank should not be overcooled as the fuel flows more slowly due to the increase in viscosity. Tanks are installed on the ground or underground.

Large fuel tanks must have ventilation holes to remove excess pressure when adding or evaporating fuel and to prevent the formation of a vacuum during fuel consumption. Bottom of the tank round shape installed at an angle of 2 degrees for sedimentation of water and precipitation. A faucet is installed at the bottom to drain water and dirt. It is often necessary to drain water from underground fuel tanks.

It is very important to respect the height difference between the large fuel tank and the service fuel tank. The maximum suction lift for the electric oil pump is 4 meters, so the bottom of the large tank must be at least 4 meters from the service fuel tank.

4.9.3 Fuel supply: for fuel lines steel pipes or flexible hoses can be used, applicable to any medium and compatible with fuel.

Note:

Do not use lead lined pipes for the fuel system.

The diameter of the fuel and return pipes must not be smaller than the outlet pipes of the generator set, while the excess pipe must be of a larger diameter (in order to ensure uninterrupted fuel supply in case of low temperatures). To connect to the engine, a flexible connection must be used to prevent breakage and leakage of fuel due to machine vibrations.

The transport pipe must take fuel at a height of at least 50 mm from the upper point of the tank bottom, as well as at a distance from the drain cock.

The purity of the fuel is very important to increase the service life and ensure the stability of the engine, so a quality filter is installed between the pump and the engine filter. At the other end of the pump there must be a tap to drain water and dirt.

4.10. Fire safety measures

During the installation of the generator set, the following measures must be taken:

The room must have a fire exit so that the operator can immediately leave the room in case of fire.
There must be a class BC/ABC fire extinguisher in the room.
The diesel engine must be connected safety valve with temperature triggering to cut off the fuel supply.

4.11. Starter batteries

Attention!

Do not smoke or allow fire or sparks near batteries as the hydrogen generated during battery charging is explosive. Batteries should be located near the engine and should be open for service as long wires can affect starting energy.

4.12. Wire connection

Generator output and load connections, as well as maintenance and repairs, must be performed by a qualified electrician with extensive experience.

Attention!

Cable connections must comply with standards and regulations, including grounding and ground loss protection.

4.12.1. Cable connection: the connection must be made with flexible cables and the alternator or circuit breaker terminals must not be damaged by the vibrations of the generator set. If there are no flexible wires during installation, one generator junction box can be installed to connect the flexible wires to the generator set. Cables must be run in pipes or ducts and must not be attached to the generating set. If a wire bend is required, consider the minimum bend diameter.

The power cables must be suitable for the output voltage and current of the generator. The room temperature, installation method, and nearby wires must be taken into account. If the wire consists of a single copper strand, then the sealed sheath must be of a non-magnetic metal such as aluminum or copper or a non-metallic material such as Teflon. If the shell is made of magnetic materials, then simple solution there will be cuts in the shell to reduce back currents.

All connection terminals must be tightened. It is very important for the circuit breaker and the generator to work in phase with the electrical network.

4.12.2. Protection: the connection between the generator and the load is protected by a circuit breaker. The circuit breaker breaks the circuit during overloads and short circuits.

when designing the power supply system, load balance must be calculated, do not overload one phase more than other phases, this can lead to overheating of the generator windings. Phase mismatch can damage sensitive 3-phase power system equipment. The current in the phase must not exceed the rated current of the generator. If it is necessary to connect the generator to an existing power branch, the distribution of electricity must be reviewed to balance the load.

4.12.4. Power factor COSc: it is necessary to calculate the power factor, COSc less than 0.8 (inductance) will lead to an overload of the generator. For normal operation, it is necessary that COS c be in the range of 0.8~1.

Keep in mind that it is necessary to prevent the occurrence of a phase advance during the installation of manual or automatic equipment for COS correction (for example, capacitor banks), because the phase advance leads to voltage instability and dangerous high voltages. In other words, all power factor correction equipment must be turned off when energized from the generator.

4.12.5. Grounding: Grounding standards vary from place to place. The generator set platform must be grounded. Ground wires must be slack to prevent breaking due to vibrations as the generator set is mounted on shock absorbers.

The ground wire must be capable of withstanding the rated current of the generator and comply with electrical safety regulations.

4.12.6. Generator switching: most alternators can switch to different output voltages. Perform switching according to the "Alternator Manual". Before changing the voltage, check that other equipment such as circuit breaker, current switch, wires and ammeter are suitable for the new voltage.

4.12.7. Simultaneous work: when several generators are running at the same time, additional equipment must be installed.

4.12.8. Insulation test: immediately after installation, check the resistance of the generator windings. Disconnect the autotransformer, short or disconnect the rotating diode pack, and disconnect all control circuits.

Use a 500V megger or similar equipment to test the resistance from the terminal to ground after disconnecting the wire between the center point and ground. The insulation resistance must be greater than 5 MΩ. If the insulation resistance is less than 5 MΩ, the winding must be prepared using the method described in the Alternator Manual.

4.13. Noise suppression

Noise suppression is very important during installation. There are several methods for noise control.

Attention!

Use noise suppression equipment while working or when moving around a running generator set.

4.13.1. Exhaust muffler: as described in section 4.8, an exhaust silencer can reduce the noise level. Different mufflers have different effects classified into 4 noise levels: work environment, home environment, high requirements and very high demands.

4.13.2. Casing: as described in paragraph 4.2. The function of the casing is to protect against rain and reduce noise. The enclosure can be specially designed to provide a certain noise level.

4.13.3. Other noise reduction methods: For indoor generators, there are many ways to reduce noise, such as noise suppression modules, separate ventilation, fan muffler, and walls with noise absorbing materials.

4.14. Transportation (Mobile Generator)

4.14.1. Transport preparation: check all parts attached to the truck and parts of the generator set for wear, breakage or missing parts. The traction force of the truck must exceed the mass of the generator by 10%.

Connect the truck and mobile generator set and then check if the connection is secure. Connect the indicator lights, connect the dimensions of the truck and chain the drawbar of the generator set. If possible, connect the security cable.

If a front screw stand is installed, tighten it with the bolt and secure the front wheel to its maximum position, allowing the rear stand to lift or lock.

Check that the tire pressures are correct, all brakes are working well and all reflectors are clean and working.

Check that all load and ground wires are disconnected, windows, tool box doors are closed and locked, check that all pipes are disconnected.

If there is a parking brake, open it and remove the blocks that fix the wheels.

4.14.2. Towing: take care that the weight of the generator set is not near or greater than the traction force of the truck, otherwise the maneuverability and braking efficiency of the truck will be reduced.

Attention!

Comply with all rules, standards and regulations traffic, including rules for equipment carried at minimum or maximum speed.

Keep your brake system in good condition.

It is prohibited to ride standing or sitting on the generator set, or to stand or sit on the drawbar of the generator set, or to stand or walk between the truck and the generator set.

Rise should be no more than 15 degrees (27%), go around holes, stones, blocks and soft ground.

Make sure there is room when driving the truck in reverse.

4.14.3. Parking place: stop the truck in a clean, dry area that can support the weight of the rig and the truck. If the truck is stopped on the slope, then the truck must be placed across the slope, the slope angle should not exceed 15 degrees (27%), apply the hand brake, set the wheel chocks, lower the front and rear lifts. Disconnect the chain, disconnect the cables and connections, then drive the truck away.

4.15. Storage:

Long-term storage has a strong effect on the engine and alternator, so the unit should be prepared to minimize this effect.

4.15.1. Diesel engine storage: preparation for storage is carried out step by step according to the instructions for the diesel engine, such as cleaning the engine, changing the oil and further preparation for storage.

4.15.2. Generator storage: during storage, warm air passes through the generator. To minimize congestion warm air in the generator, place the generator in a dry place and keep the windings with the heating wire dry.

If the generator is taken out of storage, check the condition of the insulation using the measurements described in paragraph 4.12. If the value is lower than before storage, the windings must be dried in accordance with the Alternator Manual.

If the value measured by the megger after drying is less than 1 MΩ, the insulation is broken and needs to be repaired.

4.15.3. Battery storage: Batteries must be fully charged every 12 weeks (8 weeks in tropical climates).

Exploitation

5.1. basic information

The generator set is equipped with modern electronic control. It can be fitted with one of the following control panel models: Check the model installed on your generating set. The control system allows manual and automatic control of the generating set. The diesel generator is equipped with a protection circuit that will warn or turn off the installation in the event of emergency situations. A detailed description of each function is provided in section 9.

The following preparatory work must be done before starting the set: first start and stop of the set, then normal start and stop of the genset.

5.2. Check before starting the plant (applicable to all control systems)

Perform the following checks:

Attention!

Turn off the control panel before checking the installation, as the automatic control system may start the installation without warning.

Turn off the power to the control system and the emergency stop switch.
! Do not open the radiator cap if the coolant is still hot. Do not fill a lot of coolant into a hot cooling system, otherwise the system may be damaged.
Check level diesel fuel and coolant and top up if necessary.
Attention!
! Do not smoke or allow fire to occur while refueling the fuel tank.
Check the fuel level and add if required.
Check engine fan mounting and charge alternator belt, tighten if necessary.
Check all flexible connections for integrity, tighten or replace if necessary.
Check for oxidation on the battery, clean them if necessary.
Check the electrolyte level in the battery and add distilled water if necessary. Add electrolyte if the battery is new and has never been charged.
Check the control panel and alternator for dust and dirt, dust and dirt can conduct electricity and impair cooling.
Check the air filter clogging indicator and replace the filter if it is clogged.
Clean the area around the generator and remove unsafe objects to avoid danger or bad effect on work.
Inspect the fuel supply system, cooling system, and lubrication system seals for leaks.
Regularly drain accumulated water from the exhaust system drain cock.
Check that the generator output voltage switch is in the OFF position.
Check the level in the lubrication system and add oil if necessary.
First start/stop - Control panel auto start

The following steps are performed the first time a generator set is started with an automatic transfer control system or the first time it is started after an extended period of time.

Attention!

Restart the unit by releasing the emergency button and turning it clockwise. Manually set the control switch to the STOP position, reset the fault warnings.

Carry out a pre-start check in accordance with the points in section 5.2.
Connect the battery to the engine, anode first, then cathode.
After wetting with the lubrication system, stop the accelerograph or turn it off, then press the START button on the control panel to start the unit while the oil pressure is displayed on the instrument or the main control panel.

If there is no oil pressure indication after three automatic rotations, stop the engine and look for the cause.

Attention!

Continuous starting with a malfunction in the lubrication system can lead to a buildup of unburned fuel in the exhaust system, which is potentially explosive.

Fill the fuel supply system hand pump and bleed the air from the fuel filter. (See diesel engine manual.)

Launch: set the control switch to the manual start position and press the start button. (If the generator set is cooled down and equipped with a heating system, main program heating time can be set.)

The engine should automatically start 3 times. If the engine does not start, the control system enters the Failure to Start state and the fault indicator on the control panel illuminates. In this case, check possible reasons faults in accordance with Part 9 of the Diesel Engine Manual.

Attention!

Dismantle the main part of the exhaust line and purge unburned fumes. As soon as the steam (white smoke) disappears and there are no other faults, reinstall the exhaust line and start the installation.

Check for unusual noises and vibrations.
Check for fluid leaks and exhaust system leaks.
Check for abnormal readings on the control panel, especially high temperature, very low oil pressure. Oil pressure should return to normal within 10 seconds of starting.
Check the voltage and frequency on the control panel. Voltage is the nominal voltage set by the manufacturer, the load frequency for a 50 Hz generator is set to approximately 52 Hz, the frequency for a 60 Hz generator is set to approximately 62 Hz. (The frequency of the electronic injection generator set can be set to any value close to the standard frequency.)

There are three ways to adjust the voltage: this is the potentiometer on the front control panel, adjust the voltage with the potentiometer. Fine tuning can be done with an automatic voltage regulator potentiometer mounted on the alternator junction box. The voltage can also be changed by switching the alternator winding connection, the ends of the windings are located in the junction box, see the alternator manual for details.

Attention!

Do not close open circuits when checking phases.

While the generator is running, install the meter leads to the terminals of an open circuit breaker to check the phase sequence. The work must be carried out by qualified personnel.
Stop: press the emergency button or the STOP button on the main control panel, the genset will stop.
When checking the remote launch control, release the emergency button and the remote stop button, then turn the switch to the AUTO position. When the input signal is given, the engine will start, when the remote control signal is turned off, the engine will stop.

Attention!

After receiving a stop command, the control system automatically keeps the engine running for the cooling period before stopping the engine.

Connect the load cable and the generator is ready for normal operation.

5.4. Normal Start/Stop - Auto Start Control Panel

Attention!

The unit is stopped in any case by pressing the emergency button or the STOP button on the control panel.
Before restarting the unit, release the emergency button by turning it clockwise, move the control knob to the STOP position, reset the fault indication.

Before starting the installation, check according to the instructions in Section 5.2.

Attention!

The unit cannot be started if the fault indicator is on. Press the reset button on the panel to reset the control system. Before attempting to start the installation, check that the problem has been corrected.

Manual start: check that the button emergency stop and the stop button on the control panel are released. Move control to manual position, press start button until engine starts. The automatic engine will make three attempts to start. If the engine does not start, the control system is blocked with a Fail to Start error, the fault indicator lights up, check the cause of the fault according to the instructions in section 9 of the Diesel Engine Manual.

Attention!

Unburned fuel vapors accumulated in the exhaust system may explode, remove one pipe of the exhaust system and blow it out. Once the fumes have been eliminated and there are no problems with the system, reinstall the exhaust pipe and start the generating set.

Diesel engine start

Check for unusual noises and vibrations.
Check for fluid leaks and exhaust system leaks.
Check for abnormal readings on the control panel, especially high temperature, very low oil pressure, oil pressure should return to normal within 10 seconds after starting.
Set output circuit switch to ON (handle up)
Attention!
- Load connection
The initial load is determined by the engine coolant temperature, if the engine coolant temperature is less than 20ºC, you can add an initial load equal to 50% of the rated power, if the engine coolant temperature is more than 80ºC, you can add an initial load equal to 70-100% of the rated power. Depending on the type, some large capacity generator sets (100 kVA) can run at 100% initial load.
Stop: first cut off the load with the generator output circuit breaker, then the engine should be run without load for a few minutes to cool down. Press the emergency button or the STOP button on the control panel to stop the generator set immediately.

If an immediate stop is required, press the emergency button without disconnecting the load.

5.5. Auto start/stop - Auto start panel

Perform the following operations to remotely control the start of the generator set using automatic system management.

Attention!

Press the emergency button or set the switch to the STOP position, the unit should stop anyway.
Before restarting the unit, release the emergency button by turning it clockwise, turn the control knob to the STOP position, reset the fault indication.

Check the installation before starting according to the instructions in section 5.2.
Attention!
The unit cannot be started if the fault indicator is on. Press the reset button on the panel to reset the control system. Before attempting to start the installation, check that the problem has been corrected.
Automatic start: check that the emergency stop button and all stop buttons on the remote control panel are released. Move the control switch to the AUTO position.
Set the generator set output breaker to the ON position.
The set is ready for automatic start, press the START button on the remote control panel, the genset will start when the start signal is received and stop when the start signal is removed.

Maintenance and repair

6.1. basic information

Good maintenance is a key factor in ensuring a long generator set life. Maintenance and repair must be carried out by qualified personnel. When carrying out maintenance and repairs, a record book should be kept so that the recorded information can be used in the future if necessary.

The generator set must be clean and free from accumulations of liquids such as fuel or lubricating oils inside, outside, as well as on/under/around any absorbents. The unit must be cleaned with industrial water and diluted detergent instead of flammable liquids. If the protective coating of absorbent materials is torn, it must be replaced immediately to prevent accumulation of liquid or oil on the material.

6.2. Maintenance

Maintenance requirements are different for different generator set environments. For diesel engine maintenance instructions, refer to the appropriate part of the Diesel Engine Manual. Service may be performed more frequently than recommended in the manual.

6.2.1. Daily maintenance and service after each job: for a generator that is not running, maintenance can be done once a week and an external inspection can be carried out every day or before each start. Before starting the installation, you must follow the instructions in section 5.2. Refer to the Diesel Engine Manual for diesel engine testing instructions in addition to the instructions in section 5.2.

6.2.2. For generator sets that never start, check once every two weeks and run the set for 5 minutes.

Attention!

Do not run the unit at low load for an extended period of time.

6.2.3. Gensets without load should be checked once a month, run the set for 5 minutes and for 1-2 hours with a minimum load of 50%.

6.2.4. Check the following every 6 months or 250 hours:

Test all fault protection equipment with simulated fault.
Clean all battery vents.
Tighten all exhaust system connections.
Tighten all electrical connections.
Perform special maintenance on the diesel engine as described in the Diesel Engine Manual.
Run the installation to check the operation of all control panel instruments.

6.2.5. Generator maintenance: daily maintenance of the generator is not required, it is enough to check and clean the windings if necessary. See generator maintenance instructions in section 8.2. "Alternator Manuals".

6.2.6. Diesel Engine Maintenance: Perform regular maintenance in accordance with the requirements of the Diesel Engine Manual and the instructions in the manual to maintain high performance.

6.3. Dismantling the engine and generator

The dismantling of the engine and generator is carried out in the following sequence:

Disconnect the power supply, fuel supply and additional equipment circuits (water heating jacket).
Disconnect battery charging circuits, disconnect battery connections (cathode disconnects first), remove batteries if necessary.
If the alternator has a shroud, release the shroud fastener, remove the exhaust line, then remove the cover.
Before removing the control panel with holder, disconnect all connecting wires, check whether all wires can be connected back.
If it is necessary to disconnect the engine and generator at the same time, they can be lifted by the eye bolts after unscrewing all the bolts fixing to the platform.

6.3.1. Dismantling the engine

Before dismantling the engine, disconnect flexible wires from it.
If the generator has one support with a platform, the front part of the generator must be secured with holders when dismantling the engine.
Remove the engine-to-platform bolts. Loosening the alternator fixing bolts will make it easier to remove the engine.
Remove the sewn-in cover of the generator.
Fasten the fan carefully with wooden holders, do not damage the blades.
Remove the connecting bolt between the engine and generator.
Hook the engine with a crane or lifting equipment.
Remove the bolts connecting to the outer casing.
Raise the engine until it is completely clear of the generator and platform.

6.3.2. Removing the alternator

If only the alternator is removed, the rear of the engine must be rigidly fixed.
Remove flexible connections.
Remove the alternator fixing bolts.
Remove the generator fan guard while supporting the front of the generator, secure the center shaft with a lever to reduce movement in air gap and preventing damage to bearings and windings.
Disconnect the generator from the engine as instructed in section 6.1.3.
While supporting the generator with a crane or lifting equipment, slide the entire generator back onto the main base and then lift.

Description and maintenance of diesel engine

7.1. Description of diesel engine

7.1.1. Basic principles: The source of power in the generator set is an industrial type internal combustion diesel engine designed to operate at constant speed and high efficiency. The engine is specially designed for the generator and is suitable for driving the generator. 4-stroke or 2-stroke internal compression ignition engine complete with all necessary devices providing constant drive power. Detailed information Refer to the Diesel Engine Manual for information on the engine and related equipment. This section only gives a general description of the main parts and wiring of the generating set.

Normal maintenance of the diesel engine in accordance with the instructions in the "Diesel Engine Manual" will ensure its continuous and stable operation.

7.1.2. Cooling system: The engine cooling system consists of two radiators, an efficient fan, a mechanical pump and a heater. The fan blows air over the radiator. The fan cools the surface of the engine and alternator, while the inside of the engine is cooled by fluid circulating through the radiator. The heater maintains the engine coolant temperature within the optimum operating temperature range.

Attention! Ventilation of the room is essential for cooling the generator set. Good job generator is provided with installation carried out in accordance with the instructions in section 4.7.

7.1.3. Motor Speed Control: The motor speed controller is a mechanical or electrical device that regulates the speed of the motor when the load changes. Engine speed is directly related to generator RPM, so changes in engine speed will affect the frequency of the output voltage.

The speed controller can regulate the engine speed and the amount of fuel supplied. When the load on the generator increases, the speed controller increases, and when it decreases, it reduces the fuel flow.

7.4.1. Fuel system: for medium and small gensets, the fuel system is connected directly to the fuel tank located in the genset platform. The capacity of a full service fuel tank is enough to run the engine for 4-8 hours.

The service fuel tank can be connected to a large tank for manual or automatic fuel supply. A complete description of the fuel system can be found in section 4.9. this manual. Large generator sets do not have a tank in the platform, so a separate tank must be installed nearby to supply fuel to the engine.

7.1.5. Exhaust system: one of the main functions of an exhaust system is to reduce noise and vent gas to a place where it won't cause damage. For small generator sets, the muffler and exhaust pipe are mounted directly to the engine. For larger generator sets, the exhaust system is supplied separately for user installation.

7.1.6. cut-off air valve: The shut-off valve prevents the engine from overspeeding due to gases and smoke entering the air intake system. If the engine speed is exceeded, the valve will cut off the air supply to stop the engine. Do not test the valve when the engine is under load, perform the test after stopping the engine. If it is necessary to test the valve during operation, perform the test on the motor without load. After checking, do not immediately start the engine.

Attention!

When the air supply to the exhaust system is cut off, a lot of gases are emitted from a running engine, so a pause is necessary before starting the engine again to dissipate the gases.

7.1.7. Auxiliary launch: It is not recommended to use ether as a starting aid, as this shortens the life of the engine.

7.2. Engine maintenance

The “Diesel Engine Manual” provides complete information on engine maintenance, including detailed troubleshooting instructions.

7.3. Radiator Maintenance

7.3.1. Attention: Corrosion is the main cause of radiator failure. Water and air increase the rate of corrosion. Check for leaks and fully charge the cooling system with water without allowing air to enter the system.

The radiator must be completely filled with water, otherwise the corrosion rate increases. The radiator of a non-operating unit must either be free of fluid or be filled to capacity with fluid. If possible, use distilled water or regular soft water with special additives added.

Attention!

When the unit is running, the coolant in the radiator is usually very hot and under pressure. Do not clean the radiator or disconnect the pipes until the fluid has cooled and do not work on the radiator or open the fan cover while the fan is running.

7.3.2. External cleaning: in a dusty and dirty environment, the gaps of the radiator are clogged with small stones and insects, which reduces the cooling efficiency. In this case, cleaning is usually done by a small pressure of water with detergent, steam or water spray on the front of the radiator. Spraying from the back of the radiator will move the dirt even deeper into the radiator. Cover the engine and generator when cleaning the radiator.

If the dirt is very ingrained and the above methods do not help, remove the radiator and soak it in hot alkaline water for 20 minutes, then rinse with hot water.

7.3.3. Internal cleaning: If a large amount of hard water is added or the generator is temporarily running without the addition of anti-corrosion additives due to leakage from the connections, the cooling system will become clogged with scale.

Perform descaling by following these steps:

Drain the water from the cooling system and disconnect the pipes from the engine.
Prepare a 4% acid descaling solution by adding acid to water (never add water to acid).
Mix for a few minutes, then heat the solution to a temperature of 49ºC, not higher.
Pour the solution into the pipe through the filter cap or branch, avoiding bubbling. After finishing chemical reaction, fill the radiator with heated solution.
Leave the solution in the system for a few minutes, then drain the solution back into the container through the system's bottom outlet or drain.
Check the inside of the system, if scale is still present, repeat the procedure using an 8% solution.
After removing the scale, to extinguish the acid, do the following: fill the container with water, heat to a boil and add soda in the following proportion: 500 g of soda per 20 liters of water, fill the radiator with this solution and drain back into the container.
Flush the radiator several times with this method, and finally leave the solution in the radiator for one hour. Drain the solution and flush the radiator with clean hot water.
Since limescale seals up leaks, check for leaks in the radiator at a pressure of 2 times the rated working pressure.
Before starting the engine, add anti-corrosion and anti-condensation additives to the coolant.

Description and maintenance of the generator

8.1. Description of the generator

The generator set uses a self-excited brushless generator with no slip rings or brushes that require maintenance. The control system has a voltage regulator.

8.2. Generator Maintenance

Regular testing and cleaning is expected, although maintenance is rarely performed.

On first start up, test the windings according to the Alternator Manual. If the generator serves as a backup, depending on the humidity of the storage location, the insulation is usually checked every 3-6 months, and heaters are installed in wet rooms to dehumidify the air and keep the windings dry.

Regularly check the air filter installed on the generator depending on the surrounding conditions. If it is necessary to clean the filter, remove the filter material, soak in water and wash it to better cleaning detergent can be added to the material. Dry the material well before installation.

Additionally perform regular cleaning internal and external parts of the generator, the frequency of cleaning depends on the environmental conditions near the generator set. To clean, follow these steps:

Turn off the power, wipe off all dirt, oils, water and other liquids, clean the ventilation grilles, as dirt can cause overheating of the windings or damage the insulation if it enters the windings. Remove dust and dirt with a vacuum cleaner, do not use blowing or spraying under pressure for cleaning.

Note. The Alternator Manual provides complete information on alternator maintenance, including detailed troubleshooting instructions.

Description of the control system and troubleshooting

9.1. Description and identification of the control system

9.1.1. Description: The generator set is equipped with a modern electronic control system. Depending on the requirements, the generator set is equipped with various types of control system, including the automatic start control system - the advanced automatic start control system, as well as the extended series advanced automatic start control system. If necessary, in a special control system, the relevant information will be attached additionally.

The control panel provides circuit breaker control, generator output voltage monitoring, diesel generator automatic stop, stop in case of malfunctions such as high oil pressure or high coolant temperature. Any control system is installed in accordance with the requirements of the generating set.

The output circuit switch disconnects the load to protect the output in case of overload or short circuit.

9.1.2. Identification: The model number of the control system is located on the top left corner or bottom right corner of the main controller.

9.1.3. Control Panel: Before starting the generator set, the operator must become familiar with the device and the panel controls. When operating the plant, the operator must frequently monitor the display of the device or the main controller for troubleshooting.

Control panels different models slightly different from the standard control panel shown in the figure. Several additional devices can be added. The following instruction describes each element of the control panel in detail (some models have only a part of the elements):

Voltmeter: Shows the output voltage of the alternator.
Voltmeter switch knob: The switch allows to measure line-to-line and line-to-line voltages and has an OFF position to zero the indicator when starting the unit.
Ammeter: Shows the load current. An ammeter switch is used to view the current of each phase. If the ammeter does not read while the generator is running, the ammeter switch may be in the OFF position.
Ammeter switch knob: selection of the current of each phase or setting the zero position to the OFF position.
Frequency meter: shows the generator voltage frequency. The standard output frequency is 50Hz or 60Hz (at full load) when the motor is running at constant speed under the control of the speed controller. At partial load, the frequency may be slightly higher than the standard, which is a signal to reduce the speed of rotation of the regulator. Typically, the frequency at no load is 52 Hz or 62 Hz and decreases to 50 Hz or 60 Hz at full load.
Hour meter: shows the number of hours the diesel generator has been running.
Engine Water Temperature Gauge: Displays coolant temperature from one temperature sensor. Normal operating temperature is around 85ºC, but different engines may have different operating temperatures. The operating temperature of the engine can be found in the Diesel Engine Manual.
Battery voltage indicator: shows the charge of the batteries. If the generator set is not running, normal battery voltage is 12-14V (12V battery) and 24-28V (24V battery). The indicator needle drops to 70% when the diesel generator is started and returns to its normal position when the unit is running. If the generator is charging the batteries, the voltage will be higher than when the generator set is stopped.
Engine oil pressure indicator: used to detect the engine oil pressure, starts working when the unit is started, the normal oil pressure is 240 - 410 kPa. As the generator warms up, the oil pressure increases.
Malfunction indicator: if the indicator is red, it means that the protection circuits have detected a malfunction and the system will be stopped, yellow indicates a warning.
The main control switch is a 3-position switch that controls the functions of the generator.
START position (Start)
Activates the manual start function for manual control of the generator set (Manual control)
STOP position (Stop)
Stops the installation and disables automatic startup. This position also resets faults.
AUTO position (Auto start)
The control system is ready for automatic start.
Emergency button: Red latching button to stop the diesel generator in case of an emergency and block automatic start. Turn the button clockwise to release the button.

9.2. Function of the control system in automatic operation

The automatic control system can provide manual/automatic start and stop functions for high coolant temperature, low oil pressure, and under or over speed.

The control system is located on the printed circuit board, has a fuse and can protect, control the process of starting, stopping and setting the fault protection mode.

9.2.1. Functions: Section 5. of the manual contains detailed instructions and diagrams of the generator set operation. This section gives detailed description operation of the control system.

Control Panel

Frequency meter
Voltmeter
Voltmeter switch
Voltmeter
Display
Fault indicator
Current switch
Programmable button
emergency stop
Manual/automatic switch
start button
stop button

The GU641B is an auto start control module designed to automatically start and stop diesel and gas generator sets that are not equipped with electronic engine control. The module also provides superior motor control and protection features.

The module monitors: overspeed, underspeed, charger failure, emergency stop, low oil pressure, high engine temperature, inability to start, inability to stop, and open speed sensor. The module displays the fault on the LCD display and through the LED indicators on the front panel.

The control panel displays the following warning information. Warnings reduce engine speed, reset the warning and its display on the warning indicator.

A warning	Cause
LOW OIL	Oil pressure after acceleration is less than warning point (OALM) or oil pressure is less than engine operating value.
HIGH TEMP	The coolant temperature is above the warning temperature set point (TSET).
UNDER REV	Motor speed is below the underspeed setting (UREV).
OVER REV	Motor speed above overspeed (OREV) setpoint
HIGH REV	Engine speed over speed safe work engine.
Lost rpm	No signal from speed sensor.
TRIPSTOP	An external signal to stop a running genset has been received.

The following warnings indicate non-critical faults.

A warning	Cause
CHG WARN	The voltage is less than the minimum start voltage (CHGV), due to insufficient battery charge or a broken drive belt. The warning will disappear when the voltage exceeds the start voltage.
AUTO LOCK	A stop warning is displayed when the engine is automatically started or an auto start signal is given. A warning signal is also displayed when the warning and auto start signal are cleared. Cancel automatic start to resolve the warning. Press the start button on the panel to start the engine normally.
TRIP LOCK	Receipt of a signal to cancel the automatic start of the engine. Press the Stop button to reset the trip input signal, the warning signal will disappear.

The running time of the engine without load is not limited.
The generator cannot automatically stop when operating in manual mode (MAN).
The controller cannot start the generator when the REM START/STOP inputs are connected ( remote control start and stop).

Launch stages (description)

Mode: Manual (Press START or STOP to start or stop the generator set).

Mode: Automatic (set a signal to the REM START/STOP (remote control start and stop) input to start and stop the genset).

State	Jump condition	Action	next state
READY	Launch required	Perform a pre-trigger on a pre-trigger meter	Pre-launch
	RPM>2 or fixed oil pressure or alternator voltage >10V		Stop (emergency stop)
	OFF mode selected or stop warning		Not ready
NOT READY (Not ready)	RPM<2 или не зафиксировано давление масла или напряжение генератора <10В, нет предупреждения остановки, выбран режим OFF		Ready
PRE-START	Pre-launch time has ended	Engine start (0>Fuel valve is powered on<}0{>Fuel valve energized Start engine start timing	Engine start
CRANKING (engine start)	RPM>start speed	Engine start is disabled Engine pre-start is completed	Engine operation
	D+ input activated or oil pressure detected or alternator voltage >25% of standard voltage		Engine start
	The maximum start time of the engine has ended, the first start.	Engine start is disabled Shut off the fuel supply valve Energize the stop valves Start the countdown of the break between starts	Break between engine starts
	The maximum start time of the engine has expired, the last start.	Engine start is disabled Engine pre-start is completed
CRANKING REST (Pause between starts)	The pause time between starts is over.	Turn on power to start the engine Energize the fuel valves Turn off the stop valve Start the countdown of the maximum start time of the engine	Engine start
State	Jump condition	Action	next state
START-UP	Reached 80% of normal engine speed	Preparation for applying the minimum load and starting the countdown of the stable operation time	Work
			Stop
	After 60 seconds	Shut off the fuel supply valve Energize the stop valves	Stop (cannot start engine)
RUNNING	Stop command	Completion of preparations for connecting the load. Start of cooling time	Cooling
	RPM=0 or other stop conditions	Completion of preparations for connecting the load. Disabling the fuel supply valve	Stop
	GCB closed
GCB open		Work
	RPM=0 or other stop conditions	Disconnecting the fuel supply valve Energizing the stop valve Completing the preparation for connecting the load.	Stop
COOLING	End of cooling time.	Shut off the fuel supply valve Energize the stop valves	Stop
	RPM=0 or other stop conditions	Shut off the fuel supply valve Energize the stop valves	Stop
	Run command	Starting preparations for connecting the load	Work
SHUT-DOWN (Stop)	RMP=0, oil pressure not fixed or generator voltage<10В		Training
	After 60 seconds		Stop (malfunction stop)

Fault management:

The following faults can be used:

WARN (Warning)
SHUT-DOWN (Stop)

Warning (WRN)

When a warning occurs, only fault and warning output is stopped.

Possible Warnings

Stop (SD)

When a shutdown fault occurs, the InteliLite system opens the CLOSE/OPEN generator switch, fuel solenoid valve, engine start and pre-start to stop the engine. Warning output and general stop output are closed. A warning is active or protection is not reset.

Possible stop problems.

See table of possible events.

List of warnings

Phase sequence control

The InteliLite controller monitors the alternator phase order and the voltage at the terminals or busbars. The operation of the installed controller is very important to prevent incorrect phase connection. The following warnings may appear:

Wrong phase sequence

L1, L2, L3 are fixed in the controller to determine the phase sequence. If the phases are connected in a different sequence (e.g. L1, L3, L2 or L2, L1, L3), this will be detected with a warning:

G ph opposed = wrong generator phase sequence

Negative phase polarity

Negative phase polarity defines an incorrect connection between the controller and the generator/conductive bars. The phase sequence is correct, but some phases are connected incorrectly (reversed 180º)

GEN L1 neg= negative polarity of generator phase L1

GEN L2 neg= Negative phase polarity of generator L2

GEN L3 neg= Negative phase polarity of generator L3

Wrong phase sequence and negative polarity

Combination of two warnings

G ph + L1 neg = wrong generator phase sequence and negative polarity of phase L1
G ph + L2 neg = incorrect oscillator phase sequence and negative phase L2 polarity
G ph + L3 neg = incorrect oscillator phase sequence and negative polarity of phase L3

Adviсe: the phase sequence function operates at voltages greater than 50 V on all phases and angles between phases of 120º ±20º. The definition lasts one second to smooth out instantaneous changes.

Sensor error control

The FLS sensor error is defined when the measured value from the sensor is exceeded by 6.2%.

On the controller screen, the measured value is replaced by ###.

Generator operating states

Generator set states

Init (Initialization)	The InteliLite controller performs automatic testing on power up
Not ready (Not ready)	Genset not ready to start
Prestart	Prestart procedure in progress, output disabled
Cranking	Engine start
Pause	Pause between attempts to start the engine
Starting	Completion of launch, but speed is still less than 80% of normal speed
running	Genset running at rated speed
Loaded	The generator set is running at rated speed and the GCB OPEN/CLOSE switch is closed.
Stop	Stop
Shut down	Shutdown Warning
Ready	Genset ready to go
Cooling	Cooling down before stopping the generator set

Table of possible warnings

Event type	Protection method	Output information (see list of outputs)
Wrn oil press	WRN	Yes
SD oil press	SD	Yes
Wrn water temp	WRN	Yes
SD water temp	SD	Yes
binary input	customizable	Yes
battery voltage<,>	WRN	Yes
battery flat	SD	Yes
start fail	SD	Yes
Param Fail	Is absent	Not
Vgen<,>	SD	Yes
Vgen unbl	SD	Yes
Fgen<,>	SD	Yes
Igen<,>	SD	Yes
Overload	SD	Yes
RPM over	SD	Yes
RPM under	SD	Yes
Total Stop	SD	Not
Pickup Fault	SD	Not
stop fail	SD	Yes
Wrn Service Time	WRN	Not
ChrgAlternFail	WRN	Yes

1.4 Control system options and upgrades

The control system can be equipped with a large number of options to adapt the generators to special requirements. This section describes some of the devices.

9.4.1. Pulse battery charger: maintaining battery charge even if the generator set is not operated for an extended period of time.

Rated charge current 8 A, the device is usually installed in the control panel. In some cases, a charger with a charge current of 10 A is installed. The charger requires a constant supply voltage of 220-240 V or 120 V.

Chargers are usually installed with separate switches to prevent shutdown in the event of a fault in the genset. The control system automatically disables the pulse charger during start-up and the batteries are charged by the engine charger.

One additional switch and one additional charger voltage regulator can be installed to prevent the effect of automatic reduction of charge when the batteries are close to full charge, this will speed up the charging of the batteries. However, the voltage regulator can only be used for a short time, otherwise the batteries will burn out from overcharging.

9.4.2. Heater: in cold and damp environments, the generator must remain warm and dry. There are three types of heaters installed on generator sets.

An immersion heater (engine heater) can be installed in the engine cooling system to facilitate starting and quickly connect the load. The heater has one constant unregulated temperature of 40ºC, heater power 1-3(kW) depends on the size of the generating set. For installations up to 400 kVA, one heater per 1 kW is required. Larger installations require two 1kW or 1.5kW heaters.

An anti-condensation heater (generator heater) for maintaining the temperature can also be installed in the control panel.

All three heaters require permanent 200V/240V AC power.

None of these are usually provided with a control switch, but when installed they always work well. When the system is started, the heaters turn off automatically, regardless of the presence of the switch.

9.4.3 Electric fuel pump: The fuel pump is used to transfer fuel to the supply tank from the large external tank. The fuel pump can be a 220/240V AC pump or a 12/24V DC pump. The pump is usually mounted on a platform with a float switch installed in the fuel tank. The control relay, switch, indicator and overflow switch are installed on the control panel.

The controller is mounted on the controller door with two illuminated buttons. The red button is grouped with the stop indicator and the stop button, the green button is grouped with the operation indicator and the start button.

Correct operation method: Red button in the ON position, press it together with the green button, start the fuel pump manually, the pump will work as long as the green button is pressed in manual mode.

To operate the pump in automatic mode, turn the red button to the ON position. When the fuel level is low, the float sensor installed in the fuel tank will activate the sensor DC relay. The pump will start at the same time with a green light. When the supply tank is full, the float switch will turn off the relay (PR) and stop the pump by turning off the green button.

If the operating current of the pump is higher than the rated value, an overload will be detected and the red indicator will light up.

Before starting the pump, fill it with fuel. Do not start the pump when the large tank is empty or the fuel cock is closed.

9.4.4 Speed/voltage control: There are three kinds of controllers to adjust the speed and voltage of the generator.

The engine speed is controlled by the setting of the electronic fuel control device. Accelerating when turning clockwise and decelerating when turning counterclockwise, after mechanically setting the potentiometer, it will fix the desired speed value.

One acceleration/deceleration switch is mounted on the control panel to control the speed of the motor through mechanical/hydraulic adjustments. The speed controller must be motor driven, and accelerate and decelerate the generator using a spring return switch.

The potentiometer on the control panel can adjust the voltage in the range of 5%.

9.4.5. Fault signal: There are three kinds of fault signal in addition to the standard fault indicator.

One buzzer with a signal off button installed in the control panel sounds when a malfunction occurs.

One optional buzzer mounted short distance from the control panel, powered by DC power and with a stop button on the control panel.

Relay outputs switch automatically. They can be connected to an external alarm system. The outputs will remain in the "Alarm" state until the control system is reset.

9.4.6. Automatic heating system: the heating system automatically preheats the air in the air intake system before starting the engine, so the starting process is delayed due to air heating.

9.4.7. ATS installation: when the generator is used as a backup power source for automatic power supply in the event of a mains failure, a load switch is required. The switch can transfer the load to a running diesel generator when the mains fails, and then connect the load back to the mains when the mains is restored.

This requires one dedicated ATS Load Switching Panel. The panel has MAINS AVAILABLE (mains available), MAINS ON LOAD (mains on load), GENERATOR AVALABLE (generator available) and GENERATOR ON LOAD (generator on load) outputs.

After receiving a signal of a malfunction of the power supply network, the countdown of the pause time begins, preventing the erroneous start of the diesel generator due to a power surge. If the mains voltage is not restored after a pause, the magnetic switch opens and a start signal is given to the generator set control system. Upon receiving the signal, the generator set will begin an automatic start cycle. The load transfer pause (AT) countdown begins to ensure stable operation of the generator and the generator magnetic circuit breaker opens. Then, after the load transfer time has elapsed, the magnetic switch closes and connects the load to the generator.

When the mains is restored, the control relay gives a signal, the load transfer pause countdown begins, allowing the generator to work for some time before switching and stabilizing the mains voltage. After the pause time has elapsed, the generator solenoid switch opens. A fixed delay is required before opening the generator solenoid switch and closing the mains solenoid switch. The generator should run idle for a while to cool the engine. The control system is ready to process the next mains failure signal.

9.5. Control System Fault and Troubleshooting Instructions

Malfunction	sign	Recovery
Unable to start the engine (applicable to manual control from the panel)	The engine does not run when the switch knob is turned to the START position.	Check switch operation. Check the battery voltage on the control panel, if there is no voltage information, check the fuse. If the voltage is low, charge the battery with another charger and connect. (Caution: Make sure the switch is in the “0” position when disconnecting and connecting batteries.)
Unable to start the engine (applicable to automatic operation)	A START signal is given, but the engine will not start, either on manual start or remote auto start.	Check all shutdown buttons (including remote buttons), check remote control panel signal connections. Check if the control switch is in the OFF position Check the fault indicator and reset it after the fault has been corrected. Check on the control panel for battery voltage, if there is no voltage information, check the fuse. If the voltage is low, charge the battery with another charger and connect. (Note: Make sure the switch is in the “0” position when disconnecting the batteries.) Check the starter solenoid, connect with a voltmeter to the terminal and cathode of the battery, turn the switch to the START position, if there is voltage, this means that the solenoid or starter is faulty and needs to be replaced. If there is no voltage, check for an open or short in the control panel connecting cables. Replace the control board if it is noisy.
Unable to start engine (applies to all control panels)	The motor starts to rotate but does not start or stops after 20 seconds of operation.	Check fuel level. Check that the emergency button on the outside is reset. Check the voltage at the fuel control valve coil. Check that the fuel filter and fuel lines are not clogged. If white smoke comes out of the exhaust system, fuel enters the engine. Carry out other checks according to the Diesel Engine Manual. If the ambient temperature is low, perform a warm start. Check that the fuel pressure sensor is not clogged.

Malfunction	sign	Recovery
Low battery (automatic operation)	Fault indicator LOW BATTERY VOLTAGE is lit	Check the battery voltage, 12V for a 12V battery, and 24V for a 24V battery. If the battery voltage is low when the engine is stopped, disconnect the batteries and charge with another charger or charge with the engine. If the alternator is running and the battery remains low, then the engine charger is not working, check the fan belt. If the fan belt is intact, check the engine charger according to the "Diesel Engine Manual". If the batteries do not charge, replace the batteries.
Not automatic mode warning.	NON-AUTO MODE malfunction indicator is lit	Check if the control switch is in the AUTO position. Check that the emergency button is reset. Check the condition of the circuit breaker (handle up). After troubleshooting, press the reset button to reset the fault indication.
High engine temperature warning	High water temperature warning.	Check if the motor is overloaded. Check that the radiator and ventilation systems are not blocked. Check that the ambient temperature is suitable and within the operating temperature range. Reduce load and stop unit as soon as possible, check fan belt tension. After troubleshooting, press the reset button to reset the fault indication.
	Low oil pressure warning.	Stop the unit and check the oil level. See Diesel Engine Manual. After troubleshooting, press the reset button to reset the fault indication.
Charger malfunction warning (Automatic operation)	BATTERY CHARGER FAILURE indicator lights up	Check that the charger is turned on and there is voltage at the output. Perform low battery checks. After troubleshooting, press the reset button to reset the fault indication.
Low Fuel Warning (Auto Mode with Optional Alarm)	The LOW FUEL LEVEL malfunction indicator lights up.	Check the fuel level in the service tank, and add fuel if necessary. Carry out the checks in section 9.4.3. for the fuel system. After troubleshooting, press the reset button to reset the fault indication.
Malfunction	sign	Recovery
Low coolant temperature (with optional alarm device)	Fault indicator LOWCOOLLANTTEMP is lit	Check that the immersion heater is on and working. After troubleshooting, press the reset button to reset the fault indication.
No voltage when generator is running (for all control systems)	The voltmeter shows no voltage.	Check that the voltmeter switch is not in the OFF position. Check the fuse in the generator junction box (control box). Check the voltage at the generator terminals with another voltmeter. If the voltage is normal, check the connection between the generator and the control panel. Check the voltmeter and replace if necessary. See "Alternator Manual" Check engine operation.
Generator does not produce power (for all control systems)	Generator runs but no power output	Check that the circuit switch is in the ON (handle up) position. Check the fuel control valve coil, if there is no power, check the faults in the above table.
Generator does not stop manually (for all control systems)	The generator set continues to run after stopping.	1. Check the correct positions of the control switches. 2. Check the fuel control valve (FCS) and replace if necessary.
Generator does not stop in automatic mode (automatic mode)	The generator continues to run when the remote START signal is removed.	Attention! For automatic series control systems, the genset does not stop immediately after the remote START signal is canceled, only after the engine cooldown time has elapsed. Wait 5 minutes for the unit to cool down. Press the emergency button or move the control knob to the OFF position and check that the generator has stopped. If the generator does not stop from the control panel, check the fuel control valve (FCS) and replace it if necessary.

9.6. ATS manual/automatic load transfer

When using a generator as a standby power source, one load transfer panel is required to automatically switch the power source. The load transfer panel is designed to signal the diesel generator to start when the mains fails, and transfer the load to the generator when the genset is stable, as well as transfer the load back to the mains when it is restored.

There are three types of load transfer devices:

Power supply network "=" Diesel generator
Diesel Generator "=" Diesel Generator
Diesel generator "=" Diesel generator "=" Power supply network

Attention!

Repair and connection of the internal switch must be carried out by trained personnel due to the high voltage in the panel.

9.7. Description of output circuit switch

The output circuit switch is an air circuit breaker rated to match the output power of the generator. The switch passes the rated current when it is in the ON position (handle up), if one of the phases is overloaded, the switch switches to the middle position, turning off the power supply. The switching time depends on the degree of overshoot, once the generator has been switched off, it cannot be restarted until the switch is switched to the OFF position (handle down).

Description and maintenance of the battery

10.1 Battery cells

10.1.1 General information: a rechargeable battery is a combination of several single battery cells, consisting of metal platinum and electrolyte. The electrical energy in a battery is produced by a chemical reaction, and since the chemical reaction is reversible, the batteries can be periodically charged and discharged.

10.1.2 Electrolyte: a conductive liquid called an electrolyte, which is a kind of sulfuric acid solution, and causes the metal plates to enter into a chemical reaction, and thus acts as a conductor.

10.1.3 Density b: Density is a unit of measurement related to the amount of acid in the volume of the electrolyte. The density of a battery filled with electrolyte at a temperature of 25º is 1.270 g/cm3; when the acid is diluted, the density value decreases.

The chemical reaction reduces the density of sulfuric acid as the battery discharges, so density measurement can be used to determine battery charge.

10.1.4 Hydrometer: used for direct density measurement, the device has a rounded shape, the electrolyte is drawn from the battery into the hydrometer, and then the glass transparent mark indicates the level on the scale printed on the wall of the hydrometer. Do not measure immediately after adding water to the battery, only after mixing the water with the precipitated acid by charging, this density measurement is more reliable. Moreover, after a long start of the engine from the battery, the density of the electrolyte is higher than the normal density. During fast charging of the battery, water does not have time to mix with the electrolyte.

10.1.5 High/low temperature: in tropical climates (above 32º), it is recommended to use an electrolyte with a density of 1.240 g/cm3 to prolong the life of a charged battery. For low ambient temperatures, this type of battery does not have enough power to start the engine due to the low density of the acid. For very low temperatures, in some cases, batteries with a higher density of 1.290-1.300 g/cm3 are used. Cold start capability increases with density.

10.1.6 Temperature control: hydrometer scale is graduated at 25ºC. The density of the electrolyte is regulated by increasing or decreasing the temperature relative to the initial temperature. The density increases by 0.004 g / cm3 with each increase in temperature by 5.5 ° C and decreases by 0.004 g / cm3 with a decrease in temperature by 5.5 ° C.

10.2 Battery maintenance

Attention!

Repair and maintenance work on batteries must be carried out in acid-resistant clothing and a mask or goggles. If electrolyte comes into contact with skin or clothing, wash the affected area with plenty of water.

10.2.1 Filling with electrolyte: batteries are transported dry, then an electrolyte of the appropriate density is prepared and poured into the battery. Open the covers, pour the electrolyte into each section of the battery, closing the plates to a height of 8 mm. Leave the battery for 15 minutes. Check and correct the water level if necessary.

10.2.2. First battery charge: the battery should be charged for 4 hours if the electrolyte was filled one hour ago. The battery electrolyte must be properly mixed according to the following current values, otherwise the battery may be damaged if the charging time is incorrect. Model E017 batteries are charged at 9A, for model E312 batteries, a charge current of 14A is used, for model E324, a charge current of 20A. The charge time is more than 4 hours in the following cases: if the battery has been stored for more than 3 months or the temperature is above 30ºC or above 80%, then the charge time is increased to 8 hours; if the battery has been stored for more than one year, then the charge time is 12 hours.

If the current of the charger is insufficient, it is permissible to use a current of at least 1/3 of the above values with a proportional increase in the charging time. (8 hours at 7 A replaces 4 hours at 14 A)

After the charge time has elapsed, check the electrolyte level, add acids to correct the density if necessary, then close the vent plugs.

10.2.3. Adding solution: during normal operation and charging of the battery, part of the electrolyte evaporates, so from time to time it is necessary to add water to the battery. First, clean the battery of dirt to prevent it from getting inside, and then open the vent plugs. Add distilled water, raising the level 8 mm from the plates, then close the stoppers.

10.3 Charging the battery

Attention!

Make sure the battery is being charged in a well ventilated environment free of flames and sparks.

Do not charge the battery in places without protection from wind, snow and direct water.

Remember to unplug the charger before disconnecting the battery.

To charge the batteries, you can use a stationary charger, in this case, disconnect the battery from the unit, charge the battery with an external charger.

10.3.1. Battery and charger connection: The charger must be properly connected to the mains supply:

Phase - wire 67
Middle line - wire N1
Ground - yellow/green wire
The battery is connected as follows:
Battery connection method:
Anode (+) - red wire
Cathode (-) - black wire

Connecting the charger and battery is as follows:

10.3.2. Charger operation: after connecting the charger to the battery and the mains as described above, the battery is charged in the following order:

When charging, open the filter cover or ventilation openings, check the electrolyte level, and if necessary, correct the level with water.

When using the charger, observe the charge factor. It is determined by the capacity of the battery and depends on the condition of the battery and the current charge level. After the start of the charge, the charge current will decrease and the decrease will continue with increasing voltage.

After disconnecting the charger, you need to determine the state of charge, leave the battery for a while. Then, measure the density of the electrolyte in each section of the battery.

The battery should not be heavily charged, otherwise it may break down. High temperature can also damage the battery, be careful about the temperature around the battery being charged, especially in tropical environment, the temperature should not exceed 45ºC.

10.4. Battery Charging Problems/Troubleshooting Chart

Malfunction	sign	Recovery
No charge current	Wrong connection or bad clamp	Check clamps, clean contacts
	Old battery or low battery	Change the battery or charge the battery with another charger
	No mains voltage	Replace charger mains cable
	Blown fuse	Replace fuse
	Diode failure	Replace diode
No indication on the charge indicator	Charge indicator malfunction	Replace charge indicator
Low charge current	Reduced supply voltage	Check mains voltage
	Wrong converter connection	Check if the mains voltage matches the inverter voltage
	No contact with battery terminal	Check and secure battery terminals
Charger clamp gets hot	Bad contact with the battery terminal	Strip the battery terminals and reconnect
Repeated blown fuse	Wrong fuse voltage	Replace with correct fuse
	Short circuit	Check and reconnect
Charge current does not decrease	Old or defective battery	The charger is working properly, the battery voltage does not increase to normal.

Generator maintenance and repair table

Diesel generator maintenance interval

Checked element	daily	50 hours / monthly	250 hours / 3 months	400 hours / 6 months	600 hours / yearly	1200 hours / 3 years	Of necessity
Checking fuel, oil and fluid levels	▲
Checking the fuel filter	▲
System Drive Bearing (PTO)	▲
Checking the filter replacement indicator	▲
Checking PTO and Axle Couplings		▲
Fire extinguisher check		◇
Battery check			▲
Changing the oil and oil filter			★
Checking the tension of the V-belt			▲
Checking PTO and Coupling Connections			▲
Valve clearance setting				▲
Check connection of PTO and clutch levers					▲
Cleaning the ignition unit, exhaust pipe					▲
Inspection of pipes and air intake connections					▲
Fuel filter replacement					★
Analysis of the composition of the coolant					◇
Checking/repairing the air intake system					▲
Checking the cooling system					▲
Generator setup						◇
Checking and adjusting the engine speed						▲
Engine valve clearance setting						▲
Fuel system check						▲
Turbine pressure test						▲
Checking the crankshaft, dampers						◇
Cooling system cleaning, thermostat replacement						◇
Checking the pressure of the cooling system						◇
Checking the air filter and replacing if necessary							★

Notes:

The diesel generator service interval is calculated in working hours or calendar terms, whichever comes first.
The diesel generator should also be checked and repaired depending on the total operating time. The service period and work performed will be adjusted according to usage, installation characteristics and fuel and lubricant compatibility.
The standby diesel generator needs quick start and stable operation, so carry out regular maintenance and inspection with the following times.
Symbol values in the table:
▲: check and repair, cleaning, tuning

★: replacement

◇: will contact the manufacturer or supplier if the customer is unable to repair.

□: heavy work, dismantling of a new plant or storage of the plant for a long period of time, and the necessary check after every 50 hours of operation.

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