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
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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
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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
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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.
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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
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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
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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