~~ ~ an} 950106-069001EN eae Installation Guide DIESEL GENERATOR ENGINE Doosan InfracoreForward This installation instruction is designed as a guied fot the proper insatallation of OOOSAN(DOOSAN Infracore Ltd. here: after OOSAN) generator diesel engines and to create conditions for faultless operation of the entire system and to prevent installation related malfunctions and possible consequential damage to the engine. This installation istruction applies to all DOOSAN engines for generator. Warranty claims against DOOSAN generator engines will be accepted only if this installation instruction has been complied with, | any modification to the engine installation intended by DOOSAN is planned, OOOSAN must be informed in. writing, and @ new inspection may necnessary. We reserve the right to make technical modifications in the course of further development. DOOSAN reserves the right to make change at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without noticing any obligation to equip same on models manufactured prior to date of such change. ‘The continuing accuracy of this manual cannot be guaranteed {Al ustrations used in this manual may not depict actual models or equipment and are intended as representative view for reference only, 2014.09 Doosan InfracoreTable of contents Installation Guide Generator Engine Installation Cooling Performance Test Engine storage and Preservation .. Engine unit (by packing conditions) Engine in Equipment (by storage location) Re-test of Long stored Engine1. Installation Guide Generator Engine Installation. Introduction installation of Generating set Exhaust Gas Temperature (Red Hot Phenomenon) Cooling Performance Test Introduction Cooling Performance Test. 16 16 161 Rubber Mounting load Engine Room ventilation DvBaTaaESA, 2. Air Intake, Exhaust & Intercooler System 41) Ventilation When a set with an integrally mounted radiator is installed in an engine room, the basic principle of ventilation is to eject hot air from the room and induce air at the ambient temperature outside the engine room with minimum re-circulation. (refer to bv22133408) 1DV2213604 illustrates the most suitable position of the engine in relation to the walls of the engine room. ‘The object is to get cool air in at the lowest possible point, push it through the radiator matrix and then out of the engine room The object is to get cool air in at the lowest possible point, push it through the radiator matrix and then out ‘of the engine room. ‘The temperature in the engine tom should not exceed 60 °C while the temperature of the intake air to the engine should be below 40 °C. When intake air is heated up above 40°C, This will result in @ power reduction of 2 % per § °C. For a specific power derating, refer toderating chart of ‘each engine model. DvzaTaS40R, Suitable Air flow DVaRISSEOA 2) Ventilation in Engine room a) General considerations DVv2213343A through DV2213345A describe the various arrangements of Engine, Air cleaner, Silencer which affects the ventilation efficiency.1. Installation Guide Wrong Right Wrong 1. Formation of swirls due to wide tip clearance of coo! Ing fan DVREIGAA “| Right No obstruction to induce cool air and to expel hot air 2. Air restriction due to adjacent wall (Suction Type) “Adequate tip clearance of cooling tan '3. Air restriction due to adjacent wall (Blower Type) |e Partition to avoid the entry of hot air through radiator |Installation Guide Dvearaa4aa Right 1. No lagging on the exhaust silencer 16. Lagging to avoid heat rise 2. Insufficient air intake 7. Sulficient air intake 3, Air heated by Engine radiation heat /4. Entry of hot air through open wall '5. Wrong axial distance of fan shroud 8. Cool air can be induced 8. Partition to avoid the entry of hot air 10. Right axial distance of fan shroud |1. Installation Guide Right DVaRISIASA Wrong 4. insufficient air intake 2, insufficient air intake 3. Intake air heated by Engine 4, Insufficient exhaust duct area (6. Sufficient air intake uae 5, Sufficient air intake 7. Cool air can be induced 8. Hot air heater by engine is isolated | 9. Sufficient exhaust duct area 10. Sufficient distance to end wall ») Air Inlet And Outlet + The location of Air Inlet and Outlet should be installed in a way that the engine can get cool air in at the lowest possible point, push it through the radiator matrix and then out of the building DV2213350A. + The openings of Air Inlet and Outlet should be about 25% larger than the radiator area and preferably be of the same rectangular shape DV2213951A.+ Ifa grille is fitted, then the opening should be by 25% more DV2213352A, Note) For a radiator matrix frontal area of 1.25 mé, the air outletnlet opening in the wall should have an area of 1.56 m?, ita grile is fitted then the opening should be increased to give 1.95 m2 7 a ES % 125 mt 1.25 mts 25% = 1.86 m? a8 T I Ratiator matric ahaa frontal area DVEITA1. Installation Guide Radiator matrix Air outlet or intet frontal area Grile 80% F tree area J 7 1.56 08 VILL Effective Height 14m mt Air outlet or inlet size to allow for grille Air outlet or inlet size to allow for louvered panel DvazISEA + The Air outlet duct should be desigend and installed according to DV221335A. ‘The shape of duct are common to inlet and outlet and the recommended dimension is T2 A, B= A1. Installation Guide SSS 3. Fuel system 41) Fuel tine Fuel line must be installed to avoid foreign objects infitration into engine. Excessive fuel line restriction should be also avoided to ensure smooth fuel flow without air bubble inside. Joints and fitings of fuel line ‘must be leakctight to avoid fuel leak or air infiltration, otherwise high fuel contamination, fuel leak and fire, or engine instability can occur. A referenced fuel temperature is 40°C, above which power reduction of 1% will occur every °C fuel temperature rise. DV2RI5355A High fuel temperature also reduces the fuel lubricity, Causing the wear of inner components of FIP. 2) Fuel Pipe Copper based, galvanized or zine coated material Must not be used for fuel pipe. IN - LINE V- TYPE Fuel lines inner diameter mm >o10 >012 Allowable vel supply ine restriction mbar < 135 < 300 Allowable {uel retum line restriction mbar = 600 = 6001. Installation Guide cee STATES, HeONTERLems couse TET nes [ox gyyteyrorar gre nes Geo ReuARnoKor @ DVRRISATEA 3) Fuel tank Copper plate, galvanized or zinc coated plate are not suitable for diesel fue! tank. ‘A minimum distance of 500mm between the fuel suction line and fuel return should be kept ‘An engine fuel suction line positioned 40mm above the bottom of the tank to prevent sludge and water being drawn into the fuel supply, see DV2213276A, bv22132808 "1. Installation Guide Breathing Fuel return and fuel suction diagram 4) Water in diesel fue! Always make sure that there is no tree water in the fuel or in the fuel tank. Water in the fuel causes; incomplete combustion + jammed nozzles + damage to injection pump + piston damage The water is also facilitating the growth of fungus and microbes in the fuel tank, clogging fiers. In cold weather the water will reeze and stop the fuel distribution, 5) Water separator ‘An extra water separator must be installed where daily temperature difference is significant or fuel quality can rot be maintained. Water Separator seen in DV2213276A can be provided lose by Doosan as an ‘tion supply. Parker 900 FH for IN-LINE and Parker 1000 FH for V-TYPE is recommended according to engine horse power ratings Water Sep- Applied] orator | Flow Rate | citer size | Engine Model Model coo FH | 381 | 80 mon |inine & Ve wooo [eet | someon | vio. via | DV2RTSz—08 6) Sulphur content in diesel tue! Doosan diesel engines for generator can be operated With fuels whose sulphur content is max. 0.05wt% Fuels with a sulphur content of > 0,05wt% are not Permitted as they result in increased corrosion and hence greatly reduce the service life of engines. The oil change intervals must be halves if the sulphur content is > 0.02wt%, 4. Exhaust system The exhaust system should be to eject the exhaust 928 out from engines with minimum back pressure. 41) Exhaust backpressure Excessive exhaust backpresusre will lead to loss of Power output, Poor fuel economy, high exhaust temperature, overheating and excessive smoke from the installation, The exhaust system for Doosan engines should be designed and arranged in a way that the maximum Permissible backpressure is 600mmAq (60 mbar) oF under. 12 —#)1. Installation Guide Exhaust System Diagram DV22IG54A No. | Title No. | Title | 1 Bellows 3 Silencer ~ | 2 Pipe 4 Pipe support 2) 3) Design and installation of Exhaust System At least one bellows should be installed between Engine and exhaust system. Bellows can protect the turbocharger from being damaged by heat expansion of exhaust system. Rain or condensate water should not enter the ‘exhaust system in any circumstance. For this reason, @ trap with Drain valve should be provided at the ‘exhaust system near engine. The exhaust system in the engine room must be elf= ciently lagged with high heat resistant material However, lagging of the exhaust manifolds and turbo- chargers is not permitted Exhaust Bellows To allow for heat expansion of the exhaust pipe work, Exhaust bellows should be stretched by 0.5mm for every 100*Cexhaust temperature rise and 1m exhaust pipe length, ‘in case that exhaust temperature is 500°C and exhaust pipe length is 4m, X (mm) = 0.5 x 500/100 x4 = 10 mm. Therefore, the bellows should be pre-stretched by 10mm and fitted between the engine exhaust outlet land the exhaust pipe work, Improper installation of bellows due to misalignment will result in premature failure itself, 13 1600011. Installation Guide ee 4) Multiple exhaust outlets The exhaust gases from a multiple engine instilation must not be combined into a common exhaust system 5 this can be very dangerous and could cause engine damage.The reason is that # one engine stopped when others are running, exhaust gases with ‘condensate and carbon will be forced into the exhaust system of the stopped engine and then into the fengine cylinders which can cause corrosion and engine damage later on. It a flap valve of reliable Quality is fitted in each exhaust system, multi-engine installations on one exhaust line can sometimes be accepted.Calculation of the total diameter of a ‘common exhaust follows the formula in DV2213355A, Common exhaust pipe a ae ae {= Multiple exhaust system TEE Numbers of engines | Factor K 2 | 1.32 3 1s ‘ 174 5 00 $ 2os D= is exhaust pipe diameter for one engine Kz is a factor (see table) 141. Installation Guide eo ees Exhaust Gas Temperature (Red Hot Phenomenon) 1. Description @ _eneraly, wroocharged diesel engine, operate with high exhaust gas temperature The temperature varies depending on the actual load factor. High exhaust temperatures will cause the exhaust manifold and turbine housing to become light red and (on full load almost cherry red, when viewed in the Poor light, the color wil look brighter. This phenomenon is called "Red Hot phenomenon “in general, the red color will start to appear at the exhaust manifold at approx. 500°C (before turbine) and, as the load increase, it will slowly expand towards the turbocharger. Under certain load factor, the complete exhaust mani- fold and turbine housing can be red in color. However, this is the quite normal and No engine rell- ability or durability can be affected when operating under this condition, v2aT5055 W the exhaust gas temperature should be abnormally high the reason can be the folonings and the symp- toms must be vec. (Fer t0 the Doosan engine specication sheet for exhaust gas temperature) + High intake Air temperature + High intake Air depression + High exhaust back pressure + Fauty injection timing Engine operating on overload + Exhaust gas leakage © inate air eakage 151. Installation Guide Cooling Performance Test Introduction ‘Take precautions to avoid engine overheating during cooling performance test. Otherwise, the engine damage and engine instability in Performance will occur. Cooling Performance Test 1. Derating AAs the engine typically runs in the enclosed space, the ventilation of air for combustion and cooling is the critical factor. Otherwise, loss of power, excessive ‘smoke and engine instabilly can occur. It the Exhaust pipe is not lagged property, the radia. tion heat of it can pass through air cleaner, resulting in loss of power as well as inferior cooling due to overall room temperature rise. It the site conditions should exceed the stated condi tions, then the engine must be derated in accordance with the respective engine derating chart Derating means reducing of the power output of an engine from its stand by power rating at normal cond tions so as to offset the adverse effects of altitude ‘and ambient temperature. + Ambient temperature in the derating refers to the air cleaner inlet temperature. Therefore, the engine should run at derated output with reference to the derating chart Derate(%) 35% 30% 25% 20% 15% 10% 5% 0% 0 500 1000 1500 2000 2500 3000 3500 4000 Altitude (m) (Ambient Temp} (45C) (38°C) (30°C) (25°C) + Readings of De-rating chan Given condition : OP222LCS with typical generating ‘set output 750kWe, and Atiude is 1,000m, Ambient temperature (air cleaner inlet temperature) is 45°C 41) Draw a vertical line from the point '1000" on the coor: dinate ‘Altitude (m)* DVaaTaSSEA 2) Get the intersection point between the vertical line and ambient temp (45°C) line 3) From the intersection point, draw a horizontal line to the lett and read the derating 9 % Result : As 9% derating is obtained, so the engine Should run at 683kWe (750 * 0.91) 16 o@ 1. Installation Guide eo 2, Cooling Performance Test 1) Test Procedures Cooling performance test should be carried out to prove the satistactory installation and correct power ratings. Prior to cooling test, Dummy thermostats which are fully open thermostats described in Fig. 2 should be fited for an accurate cooling test 65.96501-00328 O-Ring 165.06402-0045, ‘Dummy DVBaTSSSTA Run the generating set at full load (applying derating value), continuously at least 30 minutes until stabilized temperature has been achieved. Then measure the data related to cooling performance. By carrying out the cooling test, itis possible to calcu- late the ATB (Air to Boll) temperature. The ATB temperature is defined as ambient tempera- lure that makes coolant at radiator top tank reach its boiling point. * Ambient temperature (Ta) in the cooling test refers to the radiator inlet air temperature 2) Measuring points and Cooling Performance calculation DVzaTSS56A Measuring points T1=T9 : Radiator inlet air temperatures At least 4 points (T3, TS, 76, T8) to be measured. Two : Water outlet temperature (from engine) Twi : Water outlet temperature (to engine) Ta : Ambient air temperature ATB = 103-TwosTa Ta : Average of (T1~T9) 103 + Max radiator top tank temperature Radiator inlet air temperature("C) Water tempera- time | Power cares - ate fae kWe 13 TS 6 8 Ta Two: Twi mm) ™ | 7@ 2. Engine storage and Preservation Engine unit (by packing conditions) a Wateproot cover packing at Wooden Box packing a 22 Engine in Equipment (by storage location) 23 Storage inside Factory . wee 23 Storage outside Factory . . 23 Re-test of Long stored Engine : 24 Introduction . . . -— 24 Re-test in general 24 12. Engine storage and Preservation LL Engine unit (by packing conditions) Wateproof cover packing @ 1. Storage method 1) Store the engine in wateproof cover packing indoor protected from water / rain water, dust ete. 2) Make sure that All the openings of the engine should be closed by plastice tapes or caps. + air cleaner inlet, coolant inlet & outlet, fuel inlet & outlet, air cleaner and crankcase breather(s) 2. Inspection method Inspection intervals, Seq. Locations = _ 3 months | 6 months | 12 months |24 months + | Engine rotation , 2 | Pulley, Flywheel : anti-rust agent ° | 3 |V bet : tension check ° Anterust treatment © Spray type or , © Tantcrut veatment Flushing type ° | 5. [Rust elimination in the cooling tine ° c | 6 [Turbocharger : Supply ol to the shat Fuel Fiter, Oil Filter ; Replace i necessary 8 | Injector ; Check rust, opening pressure 9 [Engine Oil Seal ; Replace if necessary 10 |Gylinder Head ; Open inspection Rotate the crankshaft two complete revolutions to make sure the piston rings are tree. 2) Pulley, Fly-wheel : anti-rust agent + When the rust is found on the pulley or flywheel, serape it off completely. + Prepare the anti-rust agent NABAKEM LONG#2 1 Anti-rust agent Type Remark LONG#2 ‘Aerosol Shake aerosol product before use. Spray it evenly to the target objects with 20-30cm away from it 3) Check condition of V-belt and retighten or replace it necessary Antirust treatment (with a sprayer) + Prepare 10% mixture of corrosion inhibiting additive "MB40-L’ and relevant spray device corrosion inhibiting | Delution ratio with | Remark | additive Water | = | Mé40-L 10: 90 (Open the cap of Water Pump inlet. Spray the mixture of corrasian inhibitor additive into the Inlet S~ 7 times + Close the cap of Water Pump inlet 5) Anti-cust treatment (it Flushing equipment is avaliable) + Prepare 15% mixture of corrosion inhibiting additive "M640-L' and relevant flushing equipment. corrosion inhibiting | Delution ratio | Remark additive with Water Mea0-L 15 85 = Connect the inlet and outlet of the flushing equipment to the engine. 242. Engine storage and Preservation Se ! Circulate the mixture of corrosion inhibitor additive about 2 minutes, Clean off the remaining additive with air-blowing Close the inlet and outlet of the water pump. 6) Rust elimination in the cooling line Dismantle the water pump and thermostat housing to check the rust inside the cooling passage. ‘Set up the equipment to run the engine at idle Prepare 0.3% mixture of radiator cleaner 'FMC1! which 's into the cooling water tine, Radiator Cleaner | Delution ratio with Wier Remark FMc1 0.3: 98.7 Start up the engine keep it running at idle. Extend the running time of engine as the elimination of rust, Clean off the remaining additive with air-biowing, 7) Dismantie the oil delivery pipe and supply the cil to the turbocharger shat 8) Check condition of fuel fiter and oil fiter for damage F leak, replace if necessary 9), Remove injectors and check rust outside. if necessary, ‘check injector with a tester for proper functioning (check spray pattem and injection pressure) 10) Check condition of crankshat cil seal, replace if necessary, 11) Dismantie the cylinder head to check the corrosion on the cylinder liners, on the underside of the cylinder head or on the valves. Wooden Box packing 1. storage method 1) Store Wooden box in enclosed place protected from water / rain water, dust etc 2) Do not stack any material on engine box to avoid damage to engine box 2 Storage method alter extended period 1) At the time of Six months after delivery from Engine 8G, open the wooden packing and store the engine in accordance with above 'Waterproo! cover packing! 22 52. Engine storage and Preservation Engine in Equipment (by storage location) Storage inside Factory 1. Responsibiliy 1} Heavy Production quality team is responsible for storage of Engine in Equipment 2. storage method 1) Store engine box in enclosed place protected from water / rain water, dust ete 3. Inspection method on sions Inspection Intervals, 2 weeks | 2 months | 6 months | 12 months 1 |Warm up operation 2 |Pulley, Fly-wheel : check the rust outside 3 |V belt : tension check 4 [Fuel Fiter, Oi Fiter ; Replace 5 |Crankshaft Oil seal : Replace it necessary : 6 [Engine Coolant : Replace 4) Do the warm up operation at idle, avoiding the quick acceleration and load operation 2) Clean off the rust on the unpainted metal surfaces such as pulley and fly-wheel 3) Check condition of V-belt and retighten or replace if necessary 4) Check condition of fuel filer and ol filter for damage or leak, replace if necessary. 5) Check condition of crankshaft oil seal, replace if necessary, 6) Fill the radiator with clean water with antifreeze by specified volume percent Storage outside Factory 1. Responsibility 1) Quality manager of Dealer, Branch, OEM takes the responsibility of engine storage and inspection 2. storage method 4) Store the engine i Uniform temperature 3. Inspection method 1) Follow the same as above ‘Inspection method! in a dry area that has a moderate, 232. Engine storage and Preservation a! Retest of Long stored Engine Introduction When an engine is roleased from long storage for customer delivery, or is necessary to be preparede for longer storage, the re-test of engine should be performed with following procedures Re-test in general 1. Preparation for Re-test 1) Complete the storage & inspection method according to inspection intervals. 2) Engine should be installed in Equipment or coupled to the test bench, 3) Remove all protective caps, tape and wrappings from ‘connections such as Breathers, Fuel in and out, connection, Water in and out connections ete, 2 Retest procedure Shut off fuel supply. and crank the engine by means of the starter until oil prossure is indicated 2) Alter the engine has started, let it run without load approximately 5 minutes at idling speed, 3) Partial or full load operation can be done when ‘cooling water temperature is aver 60 degree and following check points should be observed and treated necessary, * Engine spm stabilty at all speed range. Starting smoke, Smoke at load condition + Abnormal or knocking sound * Cooling water temperature, oil pressure * Oil leakage, water leakage, air leakage, gas leakage + Fault Code (Electronic controlled engine only) 24