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    96 views38 pages

    Genset Manual Book

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    Yè Winț

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    © All Rights Reserved
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    Generator Set Technique Manual 1 GENERATOR SET Operation/Service/Maintenance Manual Foreword The Diesel-Generator Set is consists of engine, alternator and generator sets control panel. This manual isfor the Diesel-Generator Sets consist of all types of engines including internationally famous brand engines, such as CUMMINS, DEUTZ and PERKINS, matching with all types of alternators, This manual is a reference for the operation of equipment please refer to “Running princip!2 and conformat.orr manual” for more detail about the running principle and conformation. For proper installation and operation, please read this manual and other technique information supplied by the O.E.M before installing and operating the Generator. We use the latest technology and the highest quality components to produce the P-Series Diesel-Generatorsets, so it has high safety and satisfactory per‘ormance Incorrect installation, operation and maintenance could result in personal injury or ceath. equipments damage or shorten the life of the equiprrants, do not instali and operate the Generator Set unless you have read and understood the instructions in this manual. If you have any question or recommendation related with this manual, please do not hesitate to contact us. Thank you Data and specifications are subject fo change without notice! CONTENTS Chapter1 Safety Regulation Chapter 2 Soundproof Generator Instruction 2.1 Hardware Information: 2.2 Control panel instruction Chapter 3 Maintenance of Soundproof Generator Chapter4 General Description of Soundproof Generator Chapter Operation of Generator Set 1. Preparation for operation 2. Generator set start and stop Chapter6 Maintenance 1, Maintenance 2. Fuel Recommendations 3. Care of Fuel Supply 4. Recommended Types of Engines Oils 5. Recommended Oil Viscosities 6. Recommended Brands of Oils 7. Coolant Information 8. How to use non-amine type LLC. 31 34 32 32 32 32 33 34 34 35 35 7 Chapter 1 Safety Regulation Warning Label Locations of the Gerset is shown as follows: A: Control Panel: Incorrect operation would lead to Genenator failure, control system should operate by professional personal B: Intake: To Generator, do not put the Generator in an enclosed area, C: Hot air diseharge: For good venitlation, do not put the Generator in an enclosed area. Starting the Generator, the exhaust is very hot, keer away from the outlet. D: Exhaust outlet: Make sure there ere unlocked, E: Lift: Lifting the Generator, make sure the hook tight, eer Chapter 2 Soundproof Generator Instruction 2.1 Hardware OWL FILL \WATER FILL 2.2.Coatrol Pane instruction CONTROL PANEL eo PR-20 é wey swat oN Stop BReaKeR OFF] Lae |@ EMERGENCY STOP Bur NCTE: These control panels could also be used for single phase generator sets, just without the selector switch, CONTROL PANEL PR-30 900 ON t 4 F BREAKER O a F NOTE: These control panels could also be used for single phase generator sets, just without the selector switch Chapter 3 Maintenance of Soundproof Generator gs DANGER 4 HIGH-VOLTAGE ELECTRIC SHOCK! Don’t touch output terminals during operation. Before reconnecting load cables because of such as a change of load, be sure to shut down generator set. Be aware of high voltage applying to a shut-down unit, to its output side. With two or more generator sets paralleled to load system and one unit being in shut-down, never assuine that the load cables ‘and output terrainals of the shut-dewn set are dead: they are live with high voltage! ax] DANGER aR ENGINE EXHAUST FUMES CAN KILL! Don't use generator sets within an enclosed ares If necessary to start generator set within an enclosed tee, provide adequate ventilation. Remember this rule when you run the set in a crater-like low spot or in tunnel Observe the direction of wind carrying exhaust fumes, end take measures, as necessary, to prevent the fumes from migration tc nearby dwellings, Stay clear of all rotating and moving parts. The drive belt, pulleys anc! fan, fer instarce, of the engine ar dangerous running parts, A:ways stay clear oF them. Perform servicirg work only when the engine is not running, PB vance 4 lr e | Ss. AVOID ELECTRICAL SHOCK, PINCHING AND BURN! Secure safety before doing any maintenance work, including dally servicing, Pull off starter key and tum OFF battery switch. Attach “DO NOT OPERATE” or similar warning tag io starter switch. rites) Do NOT OPERATE Maintenance work In'progrees DAR wsnavc _asicsarery rnecavrions Shut dowm generator set upon noting something wrong! Upon noting noise, odor or vibration that is abnormal, shut down the Set immediately. Depending on the cegree abnormality, you may have to shut down instantly by pressing the emergency stop button, After shutting down the set, investigate ‘or the cause and, if you can't ‘ell what's wrong, consult your engire dealer, Never keep on running the set exhibiting abnormal noise, odor or vibration or it will soon develop major trouble or a serious acciden: ‘Avoid fire hazards! Fuel, lube oil, anti-freeze fluid ané the like are all inflammable. Don't smoke while filling the rediatcr or changing the coolant or ci Never use an open flame near the runing generator set. Be sure to perform daily end periodic inspections. Serious accidents ‘often have their beginning in pocr mainterance. Know the importance of the periodie care your generator set noeds, (Service personnel must be qualified to perfortn electrical and mechanicat service.) YR wane = % Make sure the lifting equipmest is in sound condition. (4) Don't use kinked or curled cables. Such a cable is likely to fail (break apart) while in lifting operation. (2) Wear leather gloves to protect your hands from wire whiskers when handling tiftng cables, (3) Keep sling chain straight and free from twists. A twist isa potential point of chain “uilure Remember, sling hitching points are specified. Lifting eyes of tiltable type are provided on the top. Use them, aud never take a hitch to any other part of generator set or the set in suspension may become lopsided or. for worse, will fal! off. Before lifting the set with an overhead crane, check the crane capacity and the possible method of lifting which may require two or more persons ta wait on the set by coordinating their actions with voice signals. Don’t attach sling cable or chain direct to the lifting eyes This is because the tiltable eyes present sharp corners, Make each hitch through a shackle or hook. Don’t allow anyone to stand under generator set suspended. Don’t aliow anyone to stand under a suspended generator set. Accidental slipping off of the set can cause severe personal injury or death. Qualified crave operator Only qualified operator show'ld operate crane. BE AWARE OF ACCIDENTAL FALLING OFF OF GENERATOR SET! (Care broken and sick- Locte, sepented stands, ete 9 xX ‘wid core visible through Ss auf concn © enlly st a pF Seg — ‘Twist in a chain, BE vane 4 | Mb ar anane oF rossiaue eeecraicsuockavp rine wazanar Installation ia the rain involves scme bazard! First, you have to anticipate the kazard of electric shock 7 when generator set is instalied in the rain, Before starting i up such a set, check to be sure the output cables are well protected from rain, and that the power connections and load equipment are not exposed to ri Good grounding is essential for avoiding electrical shock! Chances of getting electric shock are much greater where generator set is not grounded, (1) Grounding is required on the ‘zak-current relay at the output terminal block, on the laggings enclosures) ofthe set and lead devices. The relay has a grouiding terminal of its own, “the laggings are to be grounded individually, (2) A grounded rod, to which an B-mm’ sheathed wire is connected, gives a good ground. Make sure that the ground resistance is not grater than 100. The user is expected t0 furnish the needed grounding rads (3) Checking by your physical reaction o¢ sensory response is a taboo: always use proper instruments Don’t tie generator set into utility line. Such conrection, even to the lighting load systery of a building, is not only illegal but also dangerous because it increases the chances of electrically shocking people and of causing fire, let alone the likelihood cf generator set «leveloping trouble in itself 10 “ WARNING hh BE AWARE OF FIRE HAZARD! Install cables in flaw-tess condition! ‘A damaged load cable can lead to an accident, such as fire and electrical shock. Before installing toad cables, check to be sure they are in good condition. Repair or replace a damaged cable, if any, right way. ‘Make safe and reliable load cable connections. Do the joo right and avoid getting blamed in the future, ‘There four rules are particularly important: (1) Ciean connection parts comp.etely. No dust, no grits and no greasy matter. (2) Never leave any load cable screw snugeight: tighten exch screw good and herd! (3) Can't load cable away fiom otter output terminals. (4) Check the cables for load-carrying vapacity. Be careful not to install uncersize vables. Don" start generator set when {flammable things are nearby! “Jpflammable” includes fel oil, lube cil, anti-freeze, wiping rags, etc. When determining the place of installation, avoid sitting your generator set close to ary permanent storage facility for keeping an inflammabie terial, liquid or solid. Secure good ventilation for generator sett Keep your generator set well ventilated. It needs fresh air for its engine and for cooling purpose. Without ventilation, it will not give full performance and may raise its teirperature dangerously to cateh fire, u WARNING 3 AVOUD PERSONAL INJURY! Is your generator set level on sclid floor! ‘At the place of installation, the floor (dir- ground or paved floor) has to be levei and even. I? generator set were on a slope, it might slide or cock oy itself to cause personal injury. If the ground is irregular or sloped, put proper bolsters under the set to keep it level and stable, a WARNING aN EXHAUST FUMES CAN KILL! The exhaust smoke is poisonous gases. This fact makes it necessary to take an appropriate measure (sure as redirecting the gases leeward {rom windward) when your generator set is operated on the street or close to dwellings BS warninc 4 AVOID ELECTRICAL SHOCK! Start up the engine when the breaker is OFF! we cq Make sure the breaker is OFF before starting generator set. After starting, check and be sure the output terminals and other live parts are <=" any all clear of people: then you may close the breaker (turn the switch to = aa) ON side? to run the set under load. OFF Haye output terminal cover put om! Leaving output terminals exposed (when ge erator set is running} can ‘cause injury due to electrical shock. Keep the cover put cn securzly. Nt “hy ¥ a WARNING AVOID FIRE HAZARD Handle fuct and oil carefully ! (1) Refill the fuel or oil tank, when the engine is down and there's 10 flame of eny kind nearby. (2) Some parts of generator set that has been running are truly hot. Don’t spill oil on such parts: if you did inadvertently, be quick to wipe the spill off (3) Aer refilling, be sure to tighten the filler cap. Never leave the cap loose Use recommended fuel, lube oil and coolant! ‘The specifications as well as capacity data are given in this manual Be consistent in the selection and use of E each, Using a wrong fuel oii, for instance, will prevent generator set from given full performance and may (D4 lead to fire accident. B 2S warnine Sy DON'T GET BURNS! Keep side doors locked during operation! Keep side doors shut and locked to keep others cut, so that nobody will get burns by touching the hot parts or get caught in a running eomponent to suffer serious injury. Remember, exhaust pipe and muffler are hot! When generator set is rurning or has just been shut down, don’t put your hand to exhaust parts Open the radiator cap carefully Engine coolant is hot and under pressure when generator set is running or has just been shut down Check coolant level only fle: engine has been stooped and filler cap is cool enough to touch with your hand, Remove fi'ler cap slowly to relieve pressure. Never touch engine when it’s running or has just been stopped! Don't touch any part of engine when it's running or hes just been stopped 14 2S warntnc SSM svorw munns aNp Fine HAZARD! ‘Turn OFF battery switch before servicing! ON ‘Turn OFF battery switch before servising or your hand might “short” ive parts to draw heavy current from battery, resulting in your hands getting burns or, for worse, fire Keep water away from electrical parts! ‘When washing, keep all doors closed tight. When you've accidentally splashed water cn control panel, be sure to blow water off with compressed air: air blowing is beter than wiping with a cloth Don’t change oil when engine is hot! Wait for engine to cool off, Rerrember, oi in oil pan is very ht! 1s o Gee Oh le WARNING SAFETY PRECAUTIONS FOR BATTERY HANDLING! Battery handling rules for safety Battery emits more or less hydrogen (a highly inflammable gas). Don't use a ligh‘er near the battery, and be sure ventilation is good. Take the following precautions for battery handling: (1) Use goggles to protect ycur eyes, and wear rubber gloves. (2)___Don’t smoke in the vicinity of battery. (3) Before inspecting cr servicing battery, be sure to turn OFF battery switch, (4) Don't leave any metal object across battery terminals, less it should cause a destructiveshort circuit. (5) If you have to wke out altery, be sure to disconnect its negative(-) terminal connection first. (6) Recharge battery ica well-ventilated room, with all battery plugs removed. (1) When reconnecting battery in place, meke terminal connections t ght ancl secure: remember, 4 loose connection can spark to trigger @ ges explosion (8) In case some manual arc welding or some such job has to be performed om engine, be sure to hhave battery connection (negative) unmade (to prevent extraneous voltage from applying to battery) Flectrolyte (acid) handling rules for séfety. Benery acid is diluted sulfuric acid, Though diluted, the acid is strong enough ty bura your skin and harm your eyes aw Acid (called electrolyte) in batery is a proportioned solution, which is often measured in indirectly by taking gravity readings on it. Have an experienced 2erson refill batery with makeup acid, instead of attempting a trial-and-ertor method £2) Don't beep battery in service with its electrolyte level below the level mark, Always be sure electrolyte is up to level (Jest there should be no accicertal ges explosion). <3) When you have spilled acid onto your hand, be quick t» wash with water and soap. This applies also to your clothing. (4) In case he aci¢ gets into your eyes, wash them ‘with a 4 of fresh water without delay and go to the doctor for treatment Should you by mistake drirk the acid, the first-aid remedy is to drink as much water as you can anc chen ru:h to the doctor. TR waaninc BR Stack generator set carefully! (1) Sazking two generator sets, one over the other, is permitted. Stack po more than two sets ad first set on. Place the first set flat on its bottom, (3) On top of the first set, place three bolsters (sleepers) at the locations marked off (4) Be sure to align CG. (center of gravity) of the points ofthe first 5) When resting the second set om top of the first, lower it gently to make the softest ose @ firm, level floor to rest the cond set to the prescribed lifting landing possible. (5) After stacking, tie down the top unit to the bottom unit {secure stability for protection against against damage to the set personal injury and (7) Be sure the second set is not heavier then the first cesting on the floor. BEWARE OF CRUMBLING DOWN! w Pu aE TAGE EEE Chapter4 General Description of Soundproof Generator Esch generator set covered in th’s Manual consists of the following: Main components: Diese engine, generator, rediator, fuel tank ars! battery {All these are mounted on a common bed and housed in a sturdy sound-absorbing enclosure. (1) The generator set as a whole can be hoisted with a sling hitched, “hrough # shackle or the like, to one titable lifting eye, which is centrally located. In the set, the generator is ditectly coupled to the eagine, the to being mounted on the sommon bed through vibration absorbers (3) The contro! pane! stands in front of the generator to facilitate conto! operation “or peralleing © Outstanding Features 1. Compact in size light in weight and high output. “The engine i of turboo arged liigh-ou put diese! engine; the generator is of brushiess type, having its shell coupled direct to the engine. By logical component configurat.on and sound shielding, the cverall length. and width are minimized for space economy 2, Ensy to control and maintain From the control panel, both engine and generator can be centrally controlled with ease. The clusters of instruments oon the panel are easy to read, Doors are arranged for easy open-close action. With the maintenance-free battery, coolant reserve tank, and fuel filler accessible from cutside of the enclorur, the set can he operated for long-hour run and is adapted to periodic ispection. High-quality electricity from the generat By its 2/3-pitch winding, the brushless generator produces steady output free of rise components in the waveform. 4, Friendly-to environment performance. “The enclosure effectively contt ins the running noise by ts sourd-abscrhing sponge The vibration absorbers minimize vibration reaching te floo” through the common bed. 5. High reliability High reliability is sabstantiated by reputable performance :#cords actieved by the host of high-output diesel engines everywhere in the works 5. High portability and easy storing. It's light-weight and requires no heavy-duty hoist. Moreover, no special lifting equipment is needed. Just hook the sling tothe central iteble eye and you can hoist it readily. © Output terminal block Spent eet ra © Protective devices Incorporated 'n the generatcr set are arotective devices, by which abnormal covwitions in the set in oper and broughtto the operator's attention by mans of alarm lights, buzzer sounding, ee. In the event of serious malcondition or trouble, the breaker is actomativully tripped OF and the engin: is forced to stop, all by the working of these devices. ‘After such an automatic shutting down of the set, be sure (2 take steps according to Troubleshooting, Your subsequent restarting procedure is to begin with the starter switch turned to STOP position (lo resct the protective deviees that have operated ion are detected IN Trouble item Nature of trouble Visual indication’ Nu Paik bs Buzzer sounding _| ‘Tube ail pressure low | The aressure is down to or below ae abou! @.1SMPafl 5 kgtiem') ° 0 f= 21 ssi) 7 mana e Water temperature | The temperature is up t exceed ie 3 | high about 101C(214°F) - creuren’ | Thretpben nepal ealnpeiao st Om 3 | & | Stortiruitio [Power leakage tas occured | 3 ground load side. | || Rtgine overspeed | The sogine i siening toe fast © Reverse current | The generator set has started 10 draw power from the other unit ° ° 7 during parallel cperation’, | | INSTALLATION © General Precautions Fresh air is constantly needed by he gersrator set in duty run to sustain fue! comaustion in its diesel engine and for cooling beth generator and angine One ot! er important facts that engine exhaust gases contain a considerable amount of toxic gases. These fects, together with tie following remindes, should be iaken into account when you locate the {generator set for installation, DANGER fou are dangerous: examples ere tumnels, deep depressions. and indoor areas. Any of these to be ventilated Ly forced or natural air circulation so that good air supply can be secured and that the exhaust gases ean be Places with poor vent driven away in order to avoid personal injury «+ When using the generator set in he vicinity of homes or streets, be sure to pey attention tothe direction of exhaust ges flow and to the noise testcictions, if any, enforced in the area, «The generator set, if it bas to be operated in a dusty of scline-ich place, must oe maintenance more closely and frecuentiy to avoid the clogging up or ecrtosion ofits radiator and air cleaner amnong others. Be sure that the floor, be it dict plound ot paved one, is flat level and firm for the generator set to stand on. Never set up the set on a sloped floor + Install ng, operating or storing he genesator set in the vieiniiy ef in‘ia atevials cannot be tolerated. Keep the | and sa anti-freeze are highly inflammable. set away from any possible cause of Gre remember, its fuel oif,ube «+ Make swe gow ventilation is maintained inside the generator set in operatiun, Den’t use a covering of any kind to enclose the tuning set. Insuffsient ventilation sill decrerse power output ar: 19 in poor performance, not 10 mention the possibility of developing fire within the set itself due to abnormal rise of temperature. + In rainy weather, it is a wise practice to set up a foldable tarpaulin tent over the generator set in order to Keep it from getting wet (thus elimina:ing another cause of electrical shock), © Outdoor Installation (1) Ensure that the generator set dfaw, through its cooling-air inlet (on the control panel side) fresh air that’s free of dust particles and saline, (2) Keep the two outlets (of cooling fiom each outlet must be ee and exhaust gases) unobstructed by objects placed above them: the flow © Indoo: Instaltation (1) Secure adequate walking spaces around the generator set in position, recalling the ried to open doors, to work at the fuel filler, o perform control manipulation, and to handle the cables. (2) Seeure good room ventilation, aad extend the engine exhaust line through a wall opening to outside (3) Asnecessary, install a duct to guiée the outgoing cooling air from the outlet through an opening inthe room wall, (4) To secure the generator set to the foundation, utilize the anchor bolt heles provided in the common bed (5) The vibration absorbing éevices included in the generator set may not be effective to damp certain types of vibration. It may be necessary Fer the user to add some anti-vibration mears of his own choice. 20 xe © Lifting with Overhead Hoist FN WARNING * Closely inspect the chains, wire ropes and other lifting gear pars to be sure they are in good working order. + When handling the ropes, wear hand gloves for protection against sharp wire barbs. ‘+ Make use of the lifting eyes fitted to the housing top. Never try to make hitches to any other parts of the housing or the generator set will cock or tilt ‘when lifted off the floor or, for warse, may slip offend fall + Be sute that the rope parts hitched to the eyes will not form an angie larger than 90 degrees when tensioned. The larger the angle, the greater is the tensile stress; it could be so great as to break the tope and cause the set to make a free fall onto hard ground. As shown in the illustration (on the right), the generator set has two centrally located eye plates of tiltable type for use only in lifting the set. Take a hitch to each when lifting by using the hooks whose capacity is known. Usable lifting books VGP model Hook capacity VGP [tons minimum Relationship of lifting angle to tensile stress Lifting angle | Change in stress ‘Vertical 18) ll 30 degrees | 1.2 times 90 degrees 21 BAY warn Hitching the rope or chain direct to the eye is prohibited, Be sure to use such as a shackle or hhook. This is because the eye plate presents sharp ccorrers and might cut the rope passing the eye; Be sure to inspect the hooks ( specified for exclusive use on each VGP model) periodically and make sure their capacity is adequate Lifting and lowering with the overhead hoist must be effected in a jerk-free manner to avoid shocking the generator set. Be sure to liftit very slowly, similarly to make softest landing possible. When moving the generator set in suspension, allow no one to come under it. Hiucnad 10 ine able ove plates to make the specified grounding connections. Grourding is essential for protection from electrical shock + Never touch any elzctrical part just to see if it is live or not with voltage. * Connecting the grounding wire to water pipe or pus pipe is probibited. |. Use grounding rods (to be furnisted by the user. 2. Connect a grounding wite to the leak-current relay grounding terminal ("or the relay use only) ‘on the output terminal block. Connect another grounding wire to the body grounding terminal. “These two terminals are to 2e ground separately. 3. Ground the lagging or casing of ezch load device. 4. For the grounding wire, use a shielded wire of 8 mm? or larger, and moke sure the ground resistance is not greater thes 100 chms. Be sure to drive each grounding rod to a depth of at least 50 em (20 in.) NOTE: Don’t ground the neutral (N) phase. With this phase grounded, leed-curtent detecting ‘unetion will be impaited. © Covnecting an External Fuel Line FAY sansine If the fiel tank is te be refilled frem an external stalled fuel pipe, be sure to pipe the fuel return tine, too, so that the fuel source through a local! too, overflowing from the tank can be returned through a pipe tine direct to the source side. A return tine is indispensable because of the ‘ire hazard which fuel oil spillitg from the fuel tank presents Fuel supply trom an externat source through a pipe line is resommendable where the generator set has t0 run eact working day for long howrs, In such a scheme cf refueling, the hand-operated valves at inlet and outlet should be arranged, 28 shown on the right, 2 9 that fuel over‘lowing from the tank will be conveyed strect to the supply-s de tanie Output terminal bhck Leakcurent relay wound terminal Housing Beondlg chm al Sreunding wire, x eas 8 mim in giz. ‘At east $0 6m (20 2.) deep, ——_— © Checking or Changing Output Voltage Setting A DANGER Remember the starter switch key and sttach “DO NOT OPERATE” or similar warning tg to starter switch before changing voltage setting. AN WARNING After re-arranging bus bars on the voltage setting panel; be sure to tighten the bus bars fully. A loose bus bar in service is likely to get burt because of hheat that generator occurs a its parts in loose contact. ‘The generator set is designed to a double-vohage specification and, for this reason. it may occur to you that you have to check to see if the existing voltage setting is consonant to the electrical load it is to support. In case you have to make a chenge from the existing setting to @ new setting to sult the loed, proceed as follows: 1. Open she control panel. 2. Remove the front and side protective covers (transparent acry! covers) from the voltage setting panel. 3. By referring to the SETTING FOR OUTPUT VOLTAGE chart, check to see if the selector switches are set to match the load in terms of voltage. 4. If not rearrange the bus bars and re-set the switches. Here's how to re-arrange the bars: A bus bar has its two ends secured with bolts and ful; loosen und remove the bolt and nut at one end: turn the bar a half rotation, bringing the end up or down; and secure that end to the upper or ower terminal 5. Putback the protective cover. 6. Close the control panel, and secure it fast by driving its screws. 23 © Power Cable (Lond Cable) Information PN, YARNING For the power cables io use in supplying power to Never re-use damaged cables. Such a cable, if placed in Clectreal equipment (leed), the primary consideration service again, can cause electrical shock, current is their size. How large must the cable size be for leakage or even fire, Your use? The answer comes primarily from two factors. cable length (from unit ta toad) and load ‘current the cable has to carry. Capacity (current-carrying capacity) of a cable is the allowable maximum. If this maximum be exceeded, the cable would get ho: to suffer burning damage. The longer the cable or the smaller its size, the lower will be the supply voltage at the loud and, in extreme cases, the load will not work at all; this lowering is spoken of as voltage drop. Try to memorize the following simple formula for Cetermiring @ proper cable size and length (for three-phase 3-wire mode of supply fine): the formula Will help you make no mistake in load cable selection for your power unit, Voltage drop e (volty= US8Xlength L Cm) /size (mm?) Xeurrent! (A) “Var * Select such a cable length and size cs will ensure a Voltage drop not greater than 5% (which will be 10 volts if the supply voltage is 200 volts). * Be sure that the cable are of rubber-sheathed type. * Cables come in two types: single-core end three-vcre. For these two ‘types, the required cable size, mm’, is given in the following two charts on the basis of load current A and cable length (meters). By selecting your cables uccording to these charts (which presupposes 200-V service allowing a voltage drop of up to 10 volts), you can be sure of not exceeding the cable capacity. Rubber-sheaihed three-core cables Rubber-sheathed single-core cables (Unit: mm’) nit: mm?) _ Up [78m [idom [125m | 150m] 200m Up 75m [100m | 125m | 150m | 200m 1050 | | m i Soa [14 is [22 [22 [30 138 32130 to 50 sat & 38_| | 100A [38 [100A | 22 _{0_|_50 | 60 | [a00n Taex 38x [sox [so x [oo x 200A | 60 f0 | 100 [is 2oj2) {2 f2 [2 |p 3o0a | 109 [100 [100 ies 150" | a0") Hoon Tease ox |x! 60x Te x | 100 24 © Connecting Load Cables FR WARNING + Select rated output that meets the requirement of your expected load, keeping in mind that fong-hour operation under light ioad is hard on the engine. + Have the cable end terminated with a pressure-clamp fitting, and fasten this fitting to ‘the output terminal. If the cable conductor has to be connected direct to an owtput terminal, be sure ‘0 insert the bare conductor wire into the hole of the terminal and to secure it tight: use of pressure-clamp fittings together with this bare conductor method is not permissible. + All terminal connections mest be absolutely tight. ‘A loose connection introduces so-called contact resistance, which is often so large as to generate localized high heat, resuiting in damage to equipment. + Never connect the lod cables to the utility tine or private lighting system. Consequences of such ‘connection are electrec shock and fire accidents © Connecting a Three-Phase Load to Generator Set Pay attention to the phase sequence, which is R, S and T, marked clearly on the cutput terminal block. ‘Where a three-phase motor is drawing power through these terminals and if tte motor is found to run in reverse direction, you can correct it by merely “swapping” any two connections, R to $ and § to R fox instance; this will meke the motor run in nonnal cr forward direction For a load arrangement like the one shown on the right with No, 1, No. 2 and No.3 loads, be sure 10 ‘equalize their load capacities as closely as possible. FN sass + AR the load side, you have tc take as much precautions in making cable cornections as you took at the output terminal block. Arcing, sparking, ferininal melting and what not we but results of loose cable connection (1) The ceble connections must be kept clean af all times. (2) Be sure that the securing screws used in the ‘connections are always tight. <3) Keep ibe load cables away fiom other output termina’s (4) Take good care of the output terminal block and the SETTING FOR OUTPUT VOLTAGE ‘chart plate, keeping them neat and clean. ‘Use on open-close roeans (on each phase inthe three phase sviten, if j PREPARATION FOR USE (PRE-START INSPECTION) © Check Generator Set EN WARNING To gain access to the generstor set, be sure to open the side doors fully. These doors will be flapped in the wind to pins your hands unless they are opened properly. Open the side doors and check under and around the generator set for oil, fuel or coolant leaks. If any leak is foun, check for the cause. © Caeck Fuel Level EN WARNING a + Use only fuel of recommended quality from an honest supplier. rA De not overfill the tank tc prevent fire. / + Ifany one of the generator in paraliel operation runs out of fuel, oN load on the other generator will be increased. Check the fuel filler of the fuel taak to be sure the tank is full Refill the tank if necessary. NOTE: If the fuel tank runs out of fel during operation, the fue! system should be primed. C.) « ‘ \ © Check Engine Oil Levei (Engine Stopped) a Maia i eve between MAX ad MIN rks onthe dips. Ad wy y oil ifnecessary. NOTE. The dipstick should be withdrawn, wiped clean, reinseited, ‘and again withdrawn so that the oll level on the dipstick can be seer 26 ‘At operating temperature, engine coolant is hot and under pressure. ‘Check coolant level ONLY wien engine is stopped and :be radiator fill cap is cool enough to touch with your bare hand. Maintain coolant level between FULL and LOW marks on the reserve tank during hot weather, NOTE: Wher refilling the reserve tank, always use coolant premixed with LLC of the same concentration as before. @ Test Warning Buzzer — 1, Turn ON the battery switch. © ee =) 2. ‘Tur the starter switch key to the RUN position, 3. |. Push the emergency stop switet (buttcn) to see if all monitor \ = indicators come ON and the buzzer sounds: if not, consult your Warming buzzer engine dealer. Emergency stop switch Q@ © Check Air Cleaner Indicator Clean the element if the indicator shows Reset the indicator after ‘ Reset bution installing clean element. VPS fe STARTING BN vansins A] WARNING WARNING Make sure the circuit breaker is OFF. Electrical shock Do not operate tue generator set with protective covers, ccan cause severe personal injury death. access covers orterminal box covers removed, Make sure there is no one nex! to the generator set. Warn Keep the side dcors locked during operation to prevent ‘any pe-sonnel nearby that you are starting up any personnel from coming into contact with rotating or thot parts of the generator set Do not run the starter for more than 10 seconds at atime. Then sllow 30 secant for cooling sefore - Heating Time . Starting temperature range FC= ASC | «15°C 30°C QRS) | 522°F) Heating time 20-40 Sec. 40-60, | Prolonged heating can cause battery to discharge early, or shorten air heater life. WARM-UP RUN BS sansine + Long periods of engine warm-up is net recommended. “his can result in cachon deposits in the combustion chambers and incomplete fuel burning, * Ifthe engine operates abncrmally, stop it as soon as possible try to find the problem and its sourve,iben make necessary repairs before starting it again, ‘Warm up the engine for $ to 10 minus. ES es (hy £ © During Warm-Up a eA ‘Check engine oil pressure we Se” Observe the pressure gauge a ~ [= ; O.1SWPa = ance reous insagtenth (with engine idling) Bias NOTE: Just efter the engine hes becn started, the pressure gauge: reading will be higher than the specification because the oil temperature is low. The pressure wil gradually restore te the norraat level. Cheek for abnormal sound and vibration ‘Stop the engine by pushing the emergency stop button if sound and/or vibration is abnormal 28 eee © Inspection During Power Supply Observe the instruments and indicat on on the control pane! during power-supply operation Oitpressure gauge |—=S«(O29-05MPA | | | (3-kgticm?} | (43-85psi) Water temperature gauge 70°C-95°C (158°F-203°F) NOTE: Do not supply power to a large load when the coolant temperature is below SO°C(I22°F), BN sansisc Do not attempt to move the generator set while itis in operation Keep hanes off hot parts ~ muffler, exhaust pipe, et during operation, or immediately afer shuiting down ‘engine. . Do not use the generator set in overload condition, © Stop Supplying Power |. Openthe load-side switches, 2.” Pressthe breaker OFF switch button, Bresker OFP switch © Stop the Generator Set ‘fer the engine has been stopped and the filer cap is A 00] enough t touth with your hand. ARMING Keep hands off hot parts ~ inuffler, exhaust gipe, etc + At operating temperature, the engine coolant is hot during operation, or immediately after shutting down and under pressure. Check the coolant ievel only engine 29 |. Turn the starter switch key to the STOP position and pull the key from the switch. The engine will run urtil the coolant temperature drops, or for about 1 minute, then stops automaticaly. STOP Sa 2, Turn OFF the battery switch after the engine has corre to a complete stop. 3. Check the coolant level inthe reserve tank, Add coolant ifthe level is below LOW mack. we NOTE: When refilling the rese-ve tank, always use coolant premixed with LLC of the seme concentrat as before Do nct add water only, 4. After a short interval, check the engine cil level. Add oil f necessary 5. Check under the generator set for cil, fuel oF coolant leaks EN pancer Never touch the output terminals of ary of the sets in parallel ‘operation, even if that set happens power cables are live and the output terminals of even 4 shul-sown set are up in voltage. be in shutdown, Remember, When ore set is carrying the whole load, the demand for load might increase, tending to exceed the rated cutput capacity of that set In case. place the second set, and the third set if necessery, in parallel operation before switching their power cables on the Icad side. In this respect, the genset is equinped with manual control devices for use in ‘manuallystarting the sets in parallel operation. 30 ChapterS Operation of Generator Set 1. Preparation for operation a (2) @) 21 > 2 22 b> 2> ‘Check to be sure that switches are provided on the Icad side, ard they ate now all OFF, Mike sute the lube oil, coolant anc fuel are adequate. ‘Be sure that the conductor lines in the power ecbles from each set are properly connected to lod-side switches to provide the prescribed phase rotation. The phuse sequence is indizated on the output terininal block of each set. The simplest way of checking the rotation is to Use a three-phase motor load. The motor will run in its forward direction if it receives pawer of correc: phase rotation. ‘The generator Set start and stop Genset Manual /Auto Start Manual Operation Turn the Power switch “Key Switch” on the “Manual” position, then Press Controller Pavel “siar”.Genset will run. Auto operation > Tum the select switch “Key Switch” on the “Auto” position, Genset will sart automatically when there is a mains failure. When the Mains returr to normal, Ge:ise! will stop the wer svoply “ar Mains Genset Stop Manual stop ‘Turn the Power sw.tch “Key Switch" on the “CHP position, Genset will stop Auto stop While the controller is in “AUTO! mode and the Mains zeturn to normal, Genset will stop. 31 Chapter 6 Maintenance 1. Maintenance The following maintenance \ip will help you gain most from your generator set gy ‘WARNING € Be sureto keep the banry switch turned OFF when you inspect or service the elect © You may try to clean the set by washing with wetr, provided ther ‘YoU keep its coors shut tight to keep out water splash, Wetting the control panels in particular is vey likely to cause ‘nisoperation, Blow off water from wetted component, ifany, with compressed ain © Gil change and cooling water change may be carried out after the day's work but never down the set. The oil and cov malfunctioning or even fire immediacy after shutting ‘water could be 30 hor as to scorch the stin: wait forthe engine 1o cool off 2. Lubrication and Maintesance Chart Servicing. item } interval Every 10 service | | | hours.ordaily | Check ergine o/ level | Check fet leve Check coolait level | Every 30 sewice | Check oe or ier venglne SI | touts or monty fuel tank | Check bateryelscuaiycTevel ad specific gavity | Check insulation sian eer reedig) | (generator main ecu | Every 280 service | Check V-tetention | hows ort year [Cha | Deflection: 10t0 ISnim (0.4 100.6 In) cing tne To Every 1000 } service hours or 3 years bolts and nuts Change fuel fiter ae ve" injection Iajeetion Cheek and nozzle pres: MPa kgileny Check and adjust injection Tee engin iE Check proteccive devices for ] Check cveuit when covtacter clases operation ‘Check gauge when failure occurs | Coolant temperature rise 101°C(214°F) :0.1SMPaf 1.5 kgi/em?}(2 psi) Tivay 2000] Chea and adjust vee | service hours or 5 | clearance: yeas ‘Check turbocharger Check eiternatsr Check starter = | Check vibration damper [Every 40000 | Replace generator beerings | sence hours Every 2 years | Chang: coolert VWher required [Prime fuel system 7 | Clean tr clearer element * Change air cleaner element Wher Replace top overhaul ‘it topoverhauled [Rapids cei [Wher overhauied Perform service on the following items for a new or reconditioned generator se’, or before using the gererator set which has been stored or left standing for a teng period of time: (Servicing interval Kem Every 50 service hours Retighten bolts and nuts Change engine oit Change eng ne oil filter Every 250 service hours | Check und adjust valve clearance 43. Recommended Type of Fuel ‘The quality of fuel oil is 2 very important fector in obtaining satisfactory erg ne pertormance, long engine life, and acceptable exhaust emission levels. Use cniy fuel of recommenced quelity from an honest supplier. Overflling can cause a fire. Ws KORO, 2205 Diesel fuel oil: 50°C(122°F) 60°C (140'F) | Disiilation temperature, point _ Lela Pour point Te'C (115F) , min, below the lowest _| atmospheric temperature _ lov point emperatte 1.0, max Carbon residue on, 10" | weight percent [ = Cetane number 45,0 ~T6, nin, wider special opening _ conditions Kinematie viscosity 2.0881, min at30°C (85°F) — 8.0:S:, min, at 50°C (122°F) | 10.5e8t, min, at 40°C (104°F) 16.2654 min, at 30°C (86"F) Sulfur we ght percent “i | Water and sediment, volume | 0.1. max = = ‘Ash weight pexent ‘00%, ax Copoer stip corrosion, at 100% | NO3. max ASTMNOS - [(212"F), 3 hrs s| LIS K 2213: Discoloration NO3 Gravity, 1SM°C 39°F, 0.80-0.87 Reference 4. Care of Fuel Supply BY wansuve Shut down the engine when fueling. Do rot smoke while fueling ~ot when handling fuel containers. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire After fueling, secure filer cap. (1) Fill the diesel fuel tank at the end of the day. This will drive out maisture-laden air and prevent condensation. @) When refilling the diesel fuel tank, use clean tools, such as a hand pump, funnels, containers, hoses, etc. Wipe filer cap ciean before removing it. When operating the hand pump, keep in mind that there could be water and sedimert that has settled tothe bottom of storagetank tap the needed amount of fuel from clean top portion. —_— (G) Be sure to pour fuel through sirainer in the filler opening. Use of 2 lint-free cheese sloth is 2 good practice for keeping dirt out. 5. Recommended Types of Engine Oils Use oils that meet the engine Service Ciassification CD (M 2106C) , Proper oil selection assures cranking ability by maintaining an ol! film on cylinder wal s and bearing surfaces in a ccndition which provides low friction, and therefore, less cranking effort to achieve cranking speecs necessary for reliable starting. Improper oil selection may result in congealed oil film on cylinder walls and bearing surfaces, whieh result in high friction cranking effort, thus preventing sufficient cranking speeds for reliable starting anc affesting engine life 6. Recommended Git Viscosities 8S Two important considerations related to satisfactory engine operation under ambient temperature conditions ~ (1) the ability to crank the ending fast enough 9 assure starting, and (2) ids and more adequate lubrication of internal wearing surfeces dering starting and warmup. These considerations can be adequately met through proper grade selection, Recommended oil viscosities are shown in the chart below. Recommended Oil Viscosities 30 25-20 -1S 10-5 8 19 FR2K-CA) 8) (14) 3) G2) (50) & a ro ou viscosities VPOWER recommends all-sexson tye engine oil of SAE 10W-30 7. Recommended Brands of Otis Recommended brands of oil are shown in the chart below. 35 14] WARNING Avoid mixing oils of different brands. In most cases, different brands are not compatible witt each other and, when mixed, | can seize parts such as piston rings, cylinders, ete. on 0 abnormal:y wear moving pars. It is best to stick with one and the same brand of oil at successive service intervals Recommended Brands of Oils (Reference) Manufacturer Bri Mitsubishi Gil Diamond HDS-3 Engine Oil Shell _—_| White Paro. Super $-3 OIL CD Mobil Mobil Delvac 1300 Exxon Exxon D. A] WARNING Shut down ‘he engine when fueling, Do nct smoke while fueling —or when handling fuel containers Fuel leaked or spilled onto hot surfaces or electrical ‘components can cause a fie. After fueling, secure filler cap. 8. Coolant Specifications Water used in the engine cooling system must be soft, or as free from scale foriaing tminerals as possible and meet the requirements shown in the Specifications” chart “Coolant NOTE: Basically, armfut chemical properties and suostanzes contared in voter (28 coolant) «must mot exceed the limits but they are tclevasle up to the limits shown in the chart below: 36 T ke Chemical | “er malign os | cem aaa | Covrenion cae . snd rust__| formation 6508S | SCTE : : 0 em2sCO7F) | ear ° Electrical | lectrical ae | conductivity : Qe an | °° © 2sCOTF) | sexe en tae eattarines | cco, | pom | | ° | an ce | M alkatinit cco. PPM ne ° mh A? (10) .

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