DIESEL GENERATOR SET MANUAL HEALTH & SAFETY The Health and Safety at Work Act requires that plant and machinery used in the country shall be properly maintained and operated so that it is safe and without risks to health of the persons concerned. The equipment described in this manual has been designed and constructed in such a way as to be safe and without risks go health when properly used, provided that the following safety precautions are observed. 1.1EQUIPMENT. a) All guards and particularly the cooling fan guards must be correctly fitted before starting the engine. b) All electrical connections should be adequately terminated and the set should be checkeu to ensure it is in a safe condition before running. c) All grounding connections must be correctly made and maintained. d) All lockable panels and doors should be locked before running the set. e) Service or maintenance procedures may involve handling of heavy parts or working with equipment capable of carrying lethal voltages. Service and/or maintenance personnel must be suitably trained and should not work on the equipment alone, but should be accompanied by a person who can summon help in case of accident. f) Before working on the equipment always disable the starting controls by disconnecting the engine starter battery. 1.2 FUELAND LUBRICATION OIL Fuel and lubricating oils can cause irritation on contact with the skin. If oil is spilt on the skin, wash thoroughly, preferably with a hand cleansing-gel and water. Persons with known allergies (and those who have cut or bruised hands) who may comf into ·contact with fuel oil should wear protective gloves. 1.3 BATTERIES. lead acid batteries are safe in use provided the following simple precautions are observed. In order to ensure safety, it is essential that the battery is properly operated and maintained in accordance with the manufacturer's recommendations. People who come into contact with the lead acid electrolyte must wear protective clothing and in particular protect the eyes. a) ELECTROLYTE. The battery contains dilute sulphuric acid which is POISONOUS and CORROSIVE. It can cause burns on contact with the skin or eyes. If acid is spilt on skin, wash with copious amounts of clean water. If electrolyte gets into the EYES, wash out with copious amounts of clean water and GET IMMEDLATE MEDICALATTENTION. 3 HONNY DIESEL GENERATOR SET TECHNICAL MANUAL j' DIESEL GENERATOR SET MANUAL b) GASES. Batteries give off EXPLOSIVE gases. Keep sparks, flames and lighted cigarettes away from batteries. Do not smoke near batteries which are on charge, or do anything likely to cause sparks. SWITCH OFF THE CIRCUIT before connecting or disconnecting battery, as otherwise a spark can cause an explosion. Ensure connections are tight before switching ono Areas where batteries are kept or charged must be adequately ventilated. c) MIXING ELECTROLYTE. If concentrated electrolyte (acid) has been obtained, it is essential for it to be diluted with approved water, preferably distilled or deionised, before use. Suitable vessels for mixing are given in the Battery Appendix. Due to the considerable heat involved, glass vessels are normally unsuitable. When mixing observe the following precautions: Put the water in the mixing vessel first. THEN add the acid, slowly and cautiously, stirring continuously, and adding only a little at a time. NEVER add the water to the acid or it may splash dangerously. The operator should wear protective goggles and clothing (or old clothes) and shoes. Allow the mixture to cool to room temperature before use. 1.4ELECTRICITY. All lockable doors and panels should be locked while the set is running, and the key held by a responsible person, do not leave the key in the lock. Personnel must be able to apply the appropriate treatment for electric shock in an emergency. Only qualified suitably trained and authorized persons, who must use insulated tools, should make or break a connection to any part of the electrical circuit. Before a connection or disconnection is made, the circuits must be checked to ensure that it is safe. Do not allow metal objects to rest on the engine starting battery or fall across the terminals. The heavy current which flow when battery terminals are incorrectly connected may cause molten metal to spit out. 1.5DEGREASE AGENTS. Degrease agents of the trichlorethylene type are toxic and must be used strictly in accordance with the Manufacturer's instructions. Avoid breathing of fumes and avoid contact with skin and eyes. Use only in a well ventilated area. Use of protective clothing is recommended to protect hands, eyes and respiration. Should any contact the skin, wash with warm soapy water. If agent gets into eyes, wash with copious amounts of clean water. GET IMMEDIATE MEDICAL ATTENTION. 4 ' f DIESEL GENERATOR SET MANUAL CONTENT SECTION SECTION 1: HEALTH & SAFETY SECTION II: DESCRIPTION of EQUIPMENT SECTION III: INSTALLATION SECTION VI: COMMISSIONING SECTION V: OPETRATION SECTION VI: FAULT DIAGNOSIS SECTION VII: MAINTENANCE & SERVICING APPENDIX: WIRING DIAGRAMS CONTROL SYSTEM DESCRIPTION DIESEL GENERATOR SET MANUAL 1.6JOINT MATERIALS. Some joints and gaskets contain asbestos which is bonded as compressed fibre and encapsulated in rubber. The asbestos used is Chrystile or "white" asbestos which is generally considered to be the safest of the varieties of asbestos. The risk of asbestos from joints occurs at their edges or if the joint is spilt on disassembly of components or if the joint is subjected to abrasion. It is recommended that when stripping or rebuilding engines using any asbestos joints. 1) Undertake the work in a well-ventilated area. >proved nvolved, 2) Do not smoke. 3) To remove joints use only a hand scraping method rather than a rotary wire brush. 4) Wet the joints being remove with either oil or water to minimize the risk of being exposed to any loose particles. The chances of being exposed to dangerous levels on engine assembly or strip are very small, :ime. .y. I make :>n is tolten :e with and consequently the risk of damage to health from asbestos in engine gaskets must be regarded as extremely low, provided the above actions are implemented. 1.7 NOISE. Noise has been described as unwanted sound. In addition to causing annoyance, noise may interfere with working efficiency by inducing stress and disturbing concentration, especially where the work is difficult or highly skilled. By hindering communications and by masking warning signals noise may be the cause of accidents. . Particularly, it may damage the hearing of employed persons. A temporary hearing loss, lasting from a few seconds to a few days, may result from exposure to high sound levels for a short time. Regular exposure to lower sound levels over a long period of time may result in destruction of certain inner ear structures and a loss of hearing which is permanent and incurable. The noise level close to an unshielded generator set is normally higher than the limits for a normal factory. Ear defenders should be readily available and must be worn by all personnel who work near the generator set. Where the generator set is provided with an engine room or acoustic enclosure, then no precautions are necessary outside the enclosure, but all personnel who enter the engine enclosure must wear ear defenders. It is recommended that the following actions be taken: a) Identify and mark places where ear protectors are required. b) Control entry into ear protection areas. 5 DIESEL GENERATOR SET MANUAL SECTION I ~EALJ'H & SAFETY Page No. 1.1 EQUIPMENT 3 1.2 FUEL AND LUBRICATING OILS 1.3 BATTERIES 3 3 1.4 ELECTRICITY 4 1.5 DEGREASE AGENTS 4 1.6 JOINT MATERIALS 5 1.7 NOISE. 5 APPENDIX A -SULPHURIC ACID DATA SHEET 2 6-7 DIESEL GENERATOR SET MANUAL c) Ensure that suitable ear protectors are provided and are used. d) Ensure that people provided with ear,protectors are instructed in their care and use. APPENDIX A SULPHURIC ACID DATA SHEET TOXICOLOGY Contact with the body results in the rapid destruction of soft tissue, causing severe burns. Repeated contact with dilute solutions may cause dermatitis. OCCUPATIONAL EXPOSURE STANDARD (OES): 1 mg/m 3 (8hr TWA) CLASSIFICATION: CORROSIVE SUBSTANCE (1830) PROTECTIVE CLOTHING MUST BE WORN WHILST CARRYING OUT ANY WORK ON OR WITH BATTERIES EYES: Goggles giving total eye protection must be worn HANDS: Suitable acid-resistant gloves eg PVC. BODY: Suitable acid resistant apron and rubber boots. EMERGENCY ACTION INHALATION OF MIST: Remove from exposure. Ensure that there is a plentiful supply of fresh air. SPLASH EYE: Irrigate with copious amounts of water or eye wash solution. SPLASH ON BODY Drench affected area with and if necessary remove contaminated OR CLOTHS: clothing. DO NOT neutralise acid whilst in contact with the skin. INGESTION: Drink copious amounts of water followed by some milk of magnesia. DO NOT INDUCE VOMITING. Following emergency action, obtain medical advice/attention as soon as possible .• 6 DIESEL GENERATOR SET MANUAL SPILLAGES Neutralize as soon as possible using an alkali eg. Soda Ash, Sodium Carbonate, Sodium Bicarbonate, and flush away to a drain with large amounts of water. DO NOT ABSORB ACID ON TO SAWDUST. FIRE FIGHTING Use carbon dioxide or dry powder extinguishers. DO NOT USE WATER OR SPRAY EXTINGUISHERS. MISC. HAZARDS Owing to the violent action that occurs when water is added to concentrated acid, it is recommended that when preparing any acidic solutions, the acid should be slowly added to the water. WITH ;hair. 7 DIESEL GENERATOR SET MANUAL SECTION II DESCRIPTION ofEQUIPMENTT Page No. 2.1 GENERAL 9 2.2 DIESEL ENGINE 9 2.3 ALTERNATOR 9 2.4 CONTROLANDINSTRUMENTS 10 2.5 BATTERY 10 2.6 ENGINE PROTECTION 10 8 L GENERATOR SET MANUAL r t DESCRIPTION ofEQUIPMENTT '~ [ 2.1GENERAL. This manual has been prepared as a companion to the separate engine and alternator literature supplied with the equipment. Electricity generating equipment comprise an alternator with flexible drive coupling to a water-cooled diesel prime mover. Engine and Alternator are mounted and accurately aligned on a heavy gauge mild steel base ;frame. The engine is arranged for battery powered starting with all controls and monitoring components generally contained within a control cubicle. The equipment must be arranged within weather protecting drop-over canopy fitted with weatherproof doors to allow access to the equipment. Air splitters should be fitted at the cooling air inlet and outlet to reduce noise. 2.2DIESEL ENGINE. The prime G-driving is an industrial type diesel engine complying with IS08528-1993 Standard and GB/T 2820-1997 The diesel engine comprise the following system: 1. Engine cooling system. 2. Fuel injector system with preset engine speed governor. 3. Electrically operated fuel solenoid to control the governor injection system. 4. Electric start with heavy duty batteries. 5 .. Suitable filters for fuel oil, lubricating oil and engine air intake. ReferJo Eng!ne Ham1Q.QQ.!s_fQr mQre d~taH.~QJnfQrmaUQn_,_ 2.3ALTERNATOR. The Stamford alternator is a self-exciting, self-regulating, screen protected machine complying with GB755, BS.5000-99, VDE0530, UTE51 00, NEMA, MG1-22 CEMA, IEC34-1 ,CSA22-2 and ASI359 standard . The alternator can continuously rated for use in ambient temperatures up to 40 degrees Centigrade. The machine has a vertical drip-proof enclosure and is complete with terminal box. Included within the alternator are semi-condu_ctor circuits designed to automatically regulate the output voltage magnitude. Refer to Alternator Handbook for more detailed information. 9 DIESEL GENERATOR SET MANUAL 2.4CONTROLAND INSTRUMENTS. Generator sets display instruments will including engine parameter and alternator parameter. All control module and meters are mounted in a sheet steel control cubicle. R~f~[Jo cQn1rQlli§.1~m mf!n.Y.f!lJQr mQre d~1f!ll.~d infQrmf!tlQn~ A circuit breaker, mounted at the control panel, provides isolation on all phases at the alternator output. Non-expendable thermo-magnetic type overload protection for the alternator is included in the circuit breaker. P.V.C (Poly-vinyl-chloride) or C.S .. P (Chiaro sulphonated- polyethylene) insulated cables are used on the equipment and wiring between the control panel and the engine, excluding the starter motor leads, are contained within non-ferrous conduit wherever possible. 2.5BATTERY. Engine starter battery within all necessary current leads and battery lugs are not provided . .C.!!§.1Qm~~hQ.Y.1d S.!JQQIYlh~lr OYYMf!H~rl~s wHhJh~lr cQrr~§QQnQ.!ngJ~f!Q_s anQJ_y_g§.~ An engine-driven alternator for battery charger is supplied to maintain the battery in good condition during engine running. 2.6ENGINE PROTECTION. Strategically placed sensors are provided to detect untoward engine conditions. Such safety devices are each electrically coupled to the engine control circuit; when actuated they cause immediate shut down of the generator set; the engine controller are then locked out and the appropriate front panel indicator remains lit until the controller are manually reset. 10 GENERATOR SET MANUAL SECTION III INSTALLATION. Page No. lmeter. :tlternator eluded 3.1 GENERAL 12 3.2 SITING THE EQUIPMENT 12 3.3 PASSAGE 13 3.4 ENGINE EXHAUST 13 3.5 OUTPUT CONNECTION 13 3.6 FUEL STORAGE 14 3.7 FIRE PRECAUTIONS 16 tbles g the ded. IOd safety ISe 11 DIESEL GENERATOR SET MANUAL INSTALLATION 3.1 GENERAL The all-weather, self contained equipment does not require stringent site preparation. Foundation requirements are features of the particular site environment and are dependent upon the nature of the subsoil and drainage. Ensure the base is sufficiently firm to support the equipment. The base should be reasonably level and free from surface irregularities. Generator sets have fixed anti-vibration discs inside, It only need expanding bolts to fix generator set framework to concrete. Storage of fuel is dependent on Local Authority Regulations, and is the province of a competent local civil engineer experienced in this field. FOUNDATION BASE Shock absorber Sealing clearance at least 13mm 3.2 SITING THE EQUIPMENT Whenever possible the main axis of the generator set should coincide with the prevailing wind direction, with the outlet aperture at the down wind end so that hot cooling air is dispersed. l2 nt upon merator 1etent wind DIESEL GENERATOR SET MANUAL 3.3 PASSAGE Allow space around the equipment so that the fitted doors can be fully opened or removed. The fitted doors and windows should be closed while running the set. 3.4 ENGINE EXHAUST Exposure to diesel exhaust fumes results in acute discomfort to the throat and eyes and should be avoided. Ensure that exhaust fumes are not likely to accumulate near ground level in restricted areas, nor be drawn into nearby doors, windows or ventilation inlets. GENERATOR SET ROOM LAYOUT / Deadening Material Flexible pipe Louver with sound decrease Shock absorber Flexible connector 3.5 OUTPUT CONNECTION The sefis supplied with all control cubicle wiring complete. Terminals are provided for Supply, Load and/or indication cables. Refer to the appended circuit diagram. A table of recommended current carrying capacities for cables is included at-the end of this Section. Because of the differing site conditions, no recommendations can be made for sizing of cables. 13 DIESEL GENERATOR SET MANUAL 3.6FUEL STORAGE Whenever fuel is stored in bulk, due regard must be taken to the possibility of fire. In view of this, storage tanks or drums should preferably be located on a separate site, well away from the generator site, and should be safeguarded against un-authorized disturbance. Strict no-smoking regulations should be enforced in the vicinity of the fuel storage area, and also (when re-fuelling) at the generator site. Fuel storage capacity, ample for daily service, is included within the set container. However, most installations will additionally require some bulk storage facility, and we will be pleased to advise the requirements best suited to a particular installation. The following outline may assist with site planning. Tank Construction. Tanks and associated fuel pipes should be constructed of mild steel and have NO interior coatings; where a long inactive period is envisaged before the tank is brought into use, interior corrosion may be inhibited by using a Shell Oil preparation ENSIS 35. FUEL TANK LAYOUT The position of fuel tank should not be higher than injector and not be . . . .I lower than the inlet of fuel pump for 1.5m 0-1.5m - DO NOT USE GALVANIZED IRON. Fuel pipes and tanks constructed of galvanized iron must not be used as the zinc cladding reacts with the fuel, leading to damage of the engine injectors. 14 81ESEL GENERATOR SET MANUAL r t f rthis, ' t ~also )atings; ~ion Bulk storage tanks should be tilted so that the base level slope slightly down from the outlet and should be fitted with a drain cock at the lowest point to enable foreign matter which ••s in the tank to be drawn off at periodic intervals. Tanks should be kept as full as possible to -ttr~•r'fthe entry of moisture, a contents level gauge should be provided. An oil-tight bund wall may be required around fuel tanks to contain spillage in the event of tank "._. . . .A or over filling; this should be ascertained from the Local Authority. Bulk storage tanks may be installed below ground level. An electrically operated fuel pump should then be provided, and should be controlled by 'high' and 'low' fuel level sensors mounted Oil Drum Storage. Where it is intended to replenish the daily service fuel tank direct from fuel drums, a separate site or building should be reserved for drum storage, well removed from other installations and secured against unauthorized entry. Where opening air storage is involved, the drums should be raised from the ground on baulks of duck boarding to prevent corrosion. Any unnecessary rolling of the drums should be avoided. Provision should be made for temporary storage of drums at the generator site so that fuel can - be allowed to stand for some twenty-four hours and allow foreign matter to settle before use. When the main tank is higher than injector For 1.5m, the floater tank must be provided Floater tank 15 DIESEL GENERATOR SET MANUAL Floater tank j Lower layout for main tank & pump 3. ?FIRE PRECAUTIONS WATER CONSTITUTES A LETHAL HAZARD IN THE PRES ENE OF ELECTRICITY. Accordingly: HOSING POINTS OR WATER BUCKETS SHOULD NOT BE PROVIDED IN THE VICINITY OF GENGRATING OR DISTRIBUTING EQUIPMENT. When considering the site layout, give attention to conditions which may pertain in the event of fire.Our Engineers will be pleased to discuss the measures necessary for a particular installation. The following points are suggested as worthy of consideration. Where daily service fuel tanks are replenished by gravity feed or electrically driven pump from a remote bulk container, automatically operated fire shut-off valves should be installed. Fire extinguishing systems are available whereby foam may be pumped from external or Fire Department bulk containers direct to strategic points. Fire extinguishers should always be available near the generator set and fuel store. Very few types are suited for use on fires where both oil and electrical hazards may be present; recommended type for use in such conditions are those using BCF, Carbon-Dioxide (C02) or Dry Powder; an asbestos blanket is a useful accessory. Foam may be used for quenching oil fires which are remote from any electrical apparatus. 16 GENERATOR SET MANUAL Always keep the site clean and free from spilled oil. An insert mineral granule absorbent is ~~.,nm,Anded for this purpose, but sand may be used. However, as these absorbent, materials also absorb moisture, and are consequently dangerous the presence of electricity, as well as being abrasive, they should be kept separate from fire I lighting equipment, and personnel should be warned NOT TO USE them on the generator set or · ilsassociated distribution equipment. Dry absorbent material can be blown around by the cooling air flow, therefore, where possible, ilshould be swept up and removed before starting the generator set. tion. m nt; y 17 DIESEL GENERATOR SET MANUAL SECTION IV COMMISSIONING. Page No. 4.1 VENTING AND PRIMING 19 4.2 FUELOIL 19 4.3 LUBRICATING OIL 19 4.4 COOLANT 19 4.5 AIR FILTERS 20 4.6 BATTERY 20 4. 7 TURBOCHARGER 20 . 4.8 EARTHING 20 4.9 OFF- LOAD TESTING 21 4.10 ON- LOAD TESTING 22 4.11 FINAL CHECKING 22 18 DIESEL GENERATOR SET MANUAL COMMISSIONING. The following instructions detail the procedures to be followed when preparing the installation for use. All equipment will have been factory assembled and electrically tested, unfortunately, it is usually necessary to drain the fuel tank, engine radiator and sump. 4.1 VENTING AI RAND OILING The engine fuel feed system may have developed air pockets en-route and require venting air. Similarly, the engine lubricating system may require oiling. Full details of these procedures and the fuel and lubricating oil types to be used are given in the separately enclosed Engine Handbook. Note: That whenever the fuel tank is drained, engine fuel feed venting will probably be necessary before operation is resumed. 4.2 DIESEL FUEL OIL Generally, specifications for diesel fuel require the oil to be clean and water free, and of low sulphur content. Conformity with BS.2869: Class A 1 or A2 is usual or other suitable fuel oil. Permissible grades of oil are detailed at the Engine Operation and Maintenance Manual. From the outset, a strictly controlled routine for refueling should be initiated; fuel cleanliness is of paramount importance if the engine is to fulfil its function, and costly maintenance is to be Any fuel drums should be positioned for some twenty-four hours prior to decanting to allow foreign matter to settle the orifice surround should be wiped clean before the drum cap is removed. Any hoses and pumping apparatus must be maintained in a scrupulously clean condition. LUBRICATING OIL Fill the engine sump with lubricating oil up to the maximum mark on the dipstick. Where special ln.Jctiionts are included on the oil filler cap, these should be adhered to. That the grade of lubricant required \/viii depend upon the anticipated lowest ambient re of the generator environment, refer to Engine Operation and Maintenance Manual 19 DIESEL GENERATOR SET MANUAL 4.4COOLANT LIQUID Fill the engine radiator with corrosion inhibited water; in climatic conditions where frost is possible, an anti-freeze mixture should be added. Anti-freeze and inhibitor additives should comply with BS.3151 or certain regressions that have been shown at Engine Operation and Maintenance Manual. The concentration of any anti-freeze compound required is again dependent upon the minimum anticipated ambient temperature; manufacturer's data should be consulted. Note: That when the engine is running, the cooling system is pressurized to a few pounds per square inch (approaching 1kg/cm2); a pressure relief valve is always fitted at the engine is hot. It is important to ensure correct replacement of the radiator cap; do not attempt removal when the engine is hot. 4.5AIR FILTERS Dry element type air filters are normally fitted and no preparation is necessary. Where an oil-bath cleaner is fitted, remove the cover and fill the container with engine oil to the marked level. Ensure correct replacement of the cover. 4.6 BATTERY The Battery Appendix at the end of this Handbook should be read before commissioning the battery. It is important to follow the PUTTTING INTO SERVICE and INITIAL CHARGE instructions carefully. Failure to do so may adversely affect the life of the battery. 4.7 TURBOCHARGER The engine is fitted with a turbo-charging unit. The turbo-charger lubrication box should be topped up with engine oil when the generator set is installed and whenever the set has stood idle for more than three months, refer to Engine Operation and Maintenance Manual. 4.8 EARTHING. The System An earth lug is provided at the alternator end of the frame base, and this must be connected to a suitable earth point, which must comply with Local Regulations. 20 MANUAL no suitable earth point is provided, then an earth spike or earth mat should be used, •ICitivEmE,ss of these depends on soil conditions, and Local Authority advice should be sought. ~thave reeze ia; earth system is a vital safeguard against injury or damage should an electrical fault or •antal abuse occur, either at the generator set or in the equipment to which it is connected. a is the customer's responsibility to ensure that the equipment earth is effectively maintained times by a competent electrician, and that his instructions concerning the maintenance of earth system are rigidly adhered to. ~s per hot. MANUFACTURER AND OUR AGENTS, CANNOT ACCEPT ANY LIABILITY WHATSOEVER ACCIDENTS ARISING FROM THE USE OF AN UNEARTHED OR DEFECTIVELY EARTHED tlwhen 2.Neutral. an ed level. 1g the ons ator Earth of the alternator neutral connection will normally be decided by the customer's overall installation. Where the generator set is used as a single source, the neutral must be connected For more complex installations, the neutral earth point is selected to ensure the correct operation of protection equipment, such as earth fault detection, and also to minimize circulating earth currents. Provision for such earth must be arranged by the customer and conform to the Local Authority's recommendations. 4.9 OFF-LOAD TESTING Running the engine at no-load condition for only a few minutes. Switch-on procedures are detailed at Section VI. Shutdown immediately if a fault condition is evident. ngine tected Check particularly for: 1. An engine oil pressure reading of 2.8kg/cm (40 lb/in) or more. 2. Engine fan operation. The fan grill may have become dented or the fan belt dislodged or slackened during transit. 3. A substantial charge reading at the battery charge/discharge ammeter. 4. Leaky engine fuel lines. Any air influx will necessitate fresh venting 21 ~f the system. DIESEL GENERATOR SET MANUAL SECTIONV OPERATION Page No. 5.1 REGULAR CHECKING 24 5.2 AUTOMATIC OPERATION 25 5.3 MANUAL OPERATION 26 5.4 FAULT SHUTDOWN 26 5.5 EMERGENCY STOP 27 5.6 FAILURE TO START 27 5. 7 ENGINE OVERRUN 27 22 GENERATOR SET MANUAL OPERATION generator set is to be used every day then the levels of lubricating oil, coolant and fuel be checked at the start of each day if possible. weekly intervals inspect the fuel, lubricating and cooling systems foe leaks. "•ilu!!n the generator set is used for standby supply only, it is not essential to check oil and levels every day, but a daily visual inspection is recommended so that any serious leaks monthly intervals check the levels of lubricating oil, coolant, fuel and battery electrolyte. is recommend that the engine is run once a week for a period of one hour on at least half This ensures that the film of lubricating oil on engine bearing surfaces is maintained; the battery charge is maintained and the engine has time to reach normal running re and so reduce internal condensation. a minimum requirement the set should be once every two weeks, and if on-load running is jsoff-load running is not recommended, a compromise is then required between minimal running and maintaining the film of lubricating oil at the engine bearing surfaces see must not be run more than 250 hours without a change of lubricating oil and filters. For standby sets with running hours considerably less than 250 hours in six months, an oil should be taken for analysis at six months intervals and oil change intervals and oil intervals determined by the results of the analysis. engine is operated on a load of less than 25/30 percent of the rated-Output, certain will be observed which may give cause for concern. 23 DIESEL GENERATOR S.ET MANUAL The usual results of such operation are heavier than normal lubricating oil consumption and oil leaks from the air and exhaust manifold . This condition is particularly evident on standby generator set applications where a weekly exercise on no load is usual practice. These phenomena are due to the fact that: The cylinder temperatures are too low to ensure complete burning of all the fuel delivered. This results in an unsightly drip from the exhaust manifold junction glands or flanged joints. A further result is that of abnormal carbon build-up on the valves, piston crowns and exhaust ports. Thus the normal service interval between top overhauls may need to be reduced. To alleviate this condition the following recommendations are made: 1.Running on light load should be avoided or reduced to the minimum period. If weekly exercising on no load is carried out, the running period should be kept down to say ten minutes, or until the battery charging rate returns to normal. 2.Every year the engine or generator set should be run at least once, preferably twice, on full load (continuous rating) for four hours to burn off accumulations of carbon in the engine and exhau st system. This may require the use of a Ddummy load D. If only one run per year is used the load should be built-up gradually from zero over the four hour run. Should the engine exhibit the symptoms of fault fuel injectors by virtue of excessive smoke (not to be confused with burning of excess oil) or misfiring, then the fuel injectors should be removed and the nozzles checked on a 'pop' tester. 5.2 AUTOMATIC OPERATION The AUTO position of the CONTROL switch is pre-selected for automatic standby against failure of the mains supply. In the event of closure of the customer's Remote Start contact, outputs from the Engine Management (EMS) will energize the Fuel Solenoid Relay (FSR) and the Running Relay (RR), before feeding the load. The Fuel Solenoid (FS) will energize to open fuel supply to the engine. The supply to FS also excites charging battery alternator driven directly by the engine. The Motor Solenoid MS1 will be energized, and its contact MS1 will close to commence the cranking cycle. .• 24 L GENERATOR SET MANUAL ~. Jand r i The engine will crank for 10 seconds, with a 10 seconds rest. When engine speed increases to give an output of 21 Hz, the cranking sequence is terminated. Refer to the CQfl1fQLmQQ.!!le d~§.~fiQ1iQn_. The MANUAL setting allows manual control of generator set. Immediately the MANUAL setting IJselected, engine cranking will commence and the generator set will start and run. st Terminate the MANUAL run by setting the CONTROL knob to OFF position. Ref~rJo the CQfl1[Qlm_QQ.!!le d~§.~fiQ1iQn.. . 5.4 FAULT SHUTDOWN The control include circuits designed to automatically shutdown the equipment in the event of a fault condition. Fault conditions are listed in the following. utes, 1) Over speed 2) Low lubrication oil pressure on full 1d exhau 3) High coolant temperature In the event of automatic fault shutdown, the engine shuts down immediately. An appropriate Warning lamp is at the control panel, the engine controls are locked-out and indication persists until the controls are manually re-set. four ive RE-Set Procedure. hould Checking the relevant system and rectify the fault before attempting to re-start the set. To :GIIflcel the fault indication and release the engine control circuit, set CONTROL switch momentarily OFF position. The generator set will assume the standby condition. nst EMERGENCY STOP. The Emergency Stop pushbutton is operated to shutdown the generator set in all operating e RR), The EMERGENCY STOP button is a "Stay-put" type and is manually re-set by turning the clockwise. :salso lethe FAILURE TO START. In the event of the engine failing to start within the pre-set cranking period (three attempts to , the control system is automatically latched as in the case of fault shutdown. 25 DIESEL GENERATOR SET MANUAL A list of suggested fault, given at Section Seven, should be of assistance in event of difficult engine starting. When the fault is rectified, if the mains supply if still failed, set CONTROL switch momentarily to OFF position. 5.7 ENGINE OVERRUN. An internal timer, within the EMS, in set to give a 5 minute( adjustment) cooling overrun, when the set is selected to stop. Overrun will not occur, if the Emergency stop pushbutton is operated. 26 L GENERATOR SET MANUAL ~ f t SECTION VI FAULT DIAGNOSIS, ' .cult f Page No. ~tarily I, when 6.1 STARTER WILL NOT TURN ENGINE 29 6.2 ENGINE TURNS BUT WILL NOT FIRE 29 6.3 ENGING FIRES BUT FAILS TO RUN 30 6.4 ENGINE MISFIRES 30 6.5 LOW OIL PRESSURE 30 6.6 OVERHEATING 31 6.7 LOW FUEL PRESSURE 31 6.8 LOSS OF POWER 32 6.9 BLACK EXHAUST SMOKE (offload) 32 6.10 WHITE EXHAUST SMOKE (offload) 33 6.11 BLUE EXHAUST SMOKE 33 6.12 SMOKE UNDER LOAD 33 6.13 ALTERNAUST VOLTAGE FALLS TO BUILD UP 34 6.14 ALTERNATOR VOLTAGE LOW 34 6.15 ALTERNTAOR VOLTAGE HIGH 34 6.16 POOR VOLTAGE REGULATION 35 6.17 VOLTAGE UNSTABLE 35 27 DIESEL GENERATOR SET MANUAL FAULT DIAGNOSIS Faulty are given in order of probabilityJor each system; for more detailed information, Please refer to the Engine or Alternator Handbook as appropriate. 6.1 STARTER WILL NOT TURN ENGINE or STARTER GOES IN AND OUT OF MESH (HUNTING) POSSIBLE CAUSE ACTION TAKING Replenish with distilled water and boost Discharged battery charge to correct specific gravity. Check action of battery Charging circuit Replace battery Check for loose battery Faulty Starter Circuit lead connections Check operation of engine mounted relays Check battery connections for tightness or corrosion Defective Starter Replace starter motor Starter pinion not Engaging ~- - - - Turn engine by hand and try again - --- ~- 6.2 ENGINE TURNS BUT WILL NOT FIRE POSSIBLE CAUSE No fuel at injectors ACTION TAKING Check fuel tank level and fuel cock Check fuel solenoid linkage and electrical contacts Air in fuel system Vent system; see Engine Handbook Water or dirt in fuel Service fuel filters Faulty fuel pump Change or service pump Injector timing incorrect Re-set timing; see Engine Handbook Blocked fuel lines Vent and clean all pipes to engine - - 28 ~~- GENERATOR SET MANUAL ~~· ~lease t '~1 ENGINE FIRES BUT FAILS TO RUN POSSIBLE CAUSE Faulty fuel supply ACTION TAKING Check and vent system Faulty fuel pump Check of service pump Fuel filters choked Service fuel filter Air clean choked Service air cleaner Engine too cool Check air cleaner ' ~TIN G) Faulty injectors Change injectors; see the Engine Operation and Maintenance Manual ENGINE MISFIRES POSSIBLE CAUSE ACTION TAKING Air in fuel system Vent fuel system and check suction pipes for Leaks; see the Engine Operation and Maintenance Manual Fractured pipe Change pipe Engine too cool Change Engine Heater (if fitted) Faulty injectors Change injectors Incorrect tappet clearances Reset clearances 8.5 LOW OIL PRESSURE POSSIBLE CAUSE ACTION TAKING Low oil level Replenish sump Oil filters choked Service oil filters Relief/Bypass valve Faulty Examine and clean vale See the Engine Operation and Maintenance Manual High oil temperature See Item 6.6 29 DIESEL GENERATOR SET MANUAL The LOW OIL PRESSURE lamp at the contml panel can be lit if the engine has stopped for lack of fuel. This is not a shutdown condition and the lamp light as the engine speed drops. 6.6 OVER HEAING POSSIBLE CAUSE Coolant level low Slipping fan belts ACTION TAKING Replenish and check for leaks Adjust belt tension; see the Engine Operation and Maintenance Manual Fouled coolant system Drain, clean and refill system Choked radiator matrix Clean matrix Injection timing Incorrect Low oil level Turbo-charger failure Reset timing; see the Engine Operation and Maintenance Manual Replenish sump Inspect turbo-charger; see the Engine Operation and Maintenance Manual 6. 7 LOW LUBRICATION OIL PRESSURE POSSIBLE CAUSE ACTION TAKING Lubrication oil filters choked Service lube filters Fault relief valve Change valve Leak in suction line Locate and rectify, vent system; see the Engine Operation and Maintenance Manual Faulty lubrication pump Change or service pump 30 GENERATOR SET MANUAL LOSS OF POWER POSSIBLE CAUSE ACTION TAKING Low fuel pressure See Item 6.7 Reset timing; see the Engine Operation and Injection timing Incorrect Maintenance Manual Faulty injectors Change injectors Air clean choked Service air cleaner Incorrect tappet clearances Reset clearances Leaking joints at cylinder head of Renew joints inlet manifold Turbo-charger failure Inspect turbo-charger High exhaust back Pressure Check exhaust for restriction BLACK EXHAUST SMOKE (off load) POSSIBLE CAUSE ACTION TAKING Faulty injectors Change injectors Injection timing incorrect Reset timing Air cleaner choked Service air cleaner Turbo-charger failure Inspect turbo-charge Excessive running on light load Run at full load for at least one hour; and cylinders Check that the Cetane Number and impurity levels Low grade fuel Of fuel is compatible with Engine Manufacturer's specification. 31 DIESEL GENERATOR SET MANUAL 6.10 WHITE EXHAUST SMOKE.(off load) ACTION TAKING POSSIBLE CAUSE Faulty injectors Change injectors Coolant temperature low Check thermostat 6.11 BLUE EXHAUST SMOKE POSSIBLE CAUSE ACTION TAKING See Item 6.4 Burning oil Overhaul engine; see the Engine Operation and Maintenance Manual 6.12 SMOKE UNDER LOAD ACTION TAKING POSSIBLE CAUSE Air clean choked Service air cleaner High exhaust back pressure Service exhaust for restriction Dirty turbo-charger Service turbo-charger Faulty feed pump Change /service pump Faulty injectors Change injectors Injector timing incorrect Reset timing; see Engine Handbook Run at full load for at least one hour if exhaust does Excessive running on light load not clear then decarbonise pistons and cylinders; see Engine Handbook Check that the Cetane Number and impurity levels Low grade fuel of fuel is com- partible with Engine Manufacturer's specification 32 - - - · - · - DIESEL GENERATOR SET MANUAL 6.13 ALTERNATOR VOLTAGE FAILS TO BUILD UP POSSIBLE CAUSE Loose connections ACTION TAKING Examine all connections, tighten where necessary Excitation switch on side of Alternator Open circuit windings Close switch Isolate each winding and check for continuit Short circuit windings Examine windings for signs of burning Faulty voltage control unit Check voltage control unit; see Alternator Handbook Faulty rotating diodes Remove diodes and test; see Alternator Handbook 6.14 ALTERNATOR VOLTAGE LOW POSSIBLE CAUSE ACTION TAKING Voltage regulator set wrongly Adjust voltage on voltage regulator unit Engine speed low Check and adjust engine speed governor. Faulty voltage control unit Check voltage control unit; see Alternator Handbook 6,15 ALTERNATOR VOLTAGE HIGH POSSIBLE CAUSE ACTION TAKING Voltage regulator wrongly set Adjust voltage control on voltage regulator unit Wiring fault to voltage regulator Check and correct Faulty voltage unit Check voltage control unit Faulty voltage control unit Faulty rotating diodes ~Check voltage control unit Remove diodes and test; see Alternator Handbook 33 · DIESEL GENERATOR SET MANUAL 6.16 POOR VOLTAGE REGULATION ACTION TAKING POSSIBLE CAUSE Reduce load Excessive load Power factory outside 1.0 to 0.8 Check load for reactive component (lagging) Check and balance load Unbalanced load Severe waveform distrotion due to type Check load type of load ----··- 6.17 VOLTAGE UNSTABLE POSSIBLE CAUSE ACTION TAKING Loose connections Examine all connections, tighten where necessary Voltage control unit gain Adjust stability; see Alternator Handbook Faulty voltage regulator unit Replace voltage regulator unit 34 DIESEL GENERATOR SET MANUAL SECTION VII MAINTENANCE AND SERVICING. Page No. 7.1 SERVICING PRECAUTIONS 37 7.2 SEALED BEARINGS 37 7.3 TURBO CHARGER 37 7.4 TYPICALSCHEDULE 37 7.5 EQUIPMENT ERVICING 39 7.6 CAUTIONARYNOTES 40 35 DIESEL GENERATOR SET MANUAL MAINTENANCE AND SERVICING 7.1 SERVICING PRECAUTIONS During any engineering work on the equipment it is considered prudent to completely immobili the generator set by isolating the engine starter battery. WARNING. WHENEVER THE DOOR TO THE CONTROL CUBICLE IS OPENED, DUE REGARD MUST BE PAID TO THE POSSIBLE PRESENCE OF LETHAL VOLTAGES. 7.2 SEALED BEARINGS The alternator and fuel pump motor bearings are sealed for life and cannot be serviced of re-greased. The bearings should be checked periodically (annually) while running for overheating or noise due to vibration. Excessive vibration which develops after a period of time may be due to bearing wear. The bearing should then be changed. 7.3 TURBO-CHARGER The engine is fitted with a turbo-charging unit which must not be run without lubrication. When the generator set is installed and whenever the set has stood idle for more than three months, the turbo-charger lubrication box should be topped up with engine oil by removal of oil inlet and adding 60cc of clean engine oil to the housing. 7.4 TYPICAL SCHEDULE. The following maintenance schedule is designed as a guide for use until experience is gained to establish a schedule to meet specific operating conditions. 1.Check daily for leaks at the lubricating oil, cooling and fuel systems. 2. Check the following items monthly: C i) Engine lubricating oil level; top up if necessary 36 DIESEL GENERATOR SET MANUAL (ii) Engine coolant level ; top up if necessary. fllmobil (iii) Battery charging system. Civ) Engine radiator and connections. Cv) Coolant hoses and connections. (vi) Condition and tension of belts. (vii) Fuel level and fuel transfer pump. UST (viii) Security of all load connections at the alternator and the panel. Cix) Inspect insulation for evidence of abrasion or chafing. Cx) Security of bolts at the baseframe. (xi) Anti-vibration mounts for evidence of undue wear or fatigue. t of Cxii) Carry out engine manufacturer's checks: refer Operation and Maintenance Manual. e due CxiiD Evidence of leaks at exhaust system, repair or replace as necessary. 3.Where the engine hours run are considerably less than 250 hours in six months, take an oil sample at six months intervals and send for analysis. n. 4. Check the following items 250 hours running: three Ci) Check air filter indicator, replace air filter element if indicator shows red. of oil (ii) Check fuel line and connections. 5. Carry out the following after 250 hours running, or when indicated by oil analysis: CD Drain lubricating oil system and refill with fresh oil. (ii) Renew lubricating oil filter elements. (iii) Clean crankcase breather element. (iv) Chang fuel filter element. (v) Carry out engine manufacturer's 250 hours checks: refer Operation and maintenance Manual. 6. After 1500 hours running or annually. Carry out engine manufacturer's 1500 hours checks: refer Operation and Maintenance Manual. 37 DIESEL GENERATOR SET MANUAL 7. Check the following items annually: ~ (i) Drain and flush the cooling system and refill with inhibited water or approved anti-freeze water mixture. (ii) Tighten exhaust manifold and turbo-charger cap screws. (iii)Check turbo-charger cap screws. (iv)Drain any sediment from fuel tanks. (v)Ciean engine. (vi)Check instrumentation. (vii)Check alternator and fuel pump motor bearings for excessive noise, heat or vibration during normal running. Bearings are sealed for life and cannot be serviced or re-greased. 8. After 4500 hours running or every two years: Carry out engine manufacturer's 4500 hours check: refer Operation and Maintenance Manual. 7.5 EQUIPMENT SERVICING Minor servicing and diagnostic fault finding procedures are detailed in the Engine and Alterna Handbooks. Spares, service and advice regarding this equipment are available from manufacturer and associated Companies. Service contract are offered, providing for regular and emergency visits by experienced Servi Engineers. When communicating with manufacturer, always provide both the equipment type and serial number. 38 -_. DIESEL GENERATOR SET MANUAL 7.6 CAUTIONARY NOTES Where equipment are in continuous use in coastal areas, an eventual breakdown due to salt impregnation of the inter-winding insulation at the alternator is possible. Due to the unpredictable conditions of exposure, the manufacturers cannot normally accept responsibility for damage due to such corrosion. Where equipment is operated in a salt-laden environment, it is advisable to strip the alternator. periodically and thoroughly flush the windings using a pressurized steam jet. Alternator breakdown due to failure of the inter-winding insulation usually results in a complete loss of output voltage with little prior warning of an untoward condition. End of the Manual 39