OPERATING AND MAINTENANCE

MANUAL

www.himoinsa.com
GAS GENERATOR SETS

HGD 440 T6NG

GAS GENERATOR
INDEX
3 1. INTRODUCTION
4 2. SAFETY STANDARDS
14 3. GENERIC DESCRIPTION
20 4. OPERATING CONDITIONS
28 5. USING THE GENERATOR SET
38 6. LPG RENTAL EQUIPMENT
43 7. MAINTENANCE
45 8. WARRANTY

PAGE 2
1. INTRODUCTION
This manual aims to provide the information and basic instructions for proper
installation, transport, maintenance and use of your generator set.
It is essential that all the safety rules and warnings are read carefully before,
during and after the generator set has been put into operation; only in this way
can we ensure optimum, regular service under perfect conditions of reliability and
safety.
This a general document used for a wide range of products with a variety of
optional features. It is possible that there are components, instructions or safety
standards mentioned in this manual which are not applicable or are insufficient
for the specific genset that has been acquired. In this case you must evaluate
and determine which instructions are valid for your genset, supplementing them
if necessary. Consult the HIMOINSA Technical Department in the event of any
doubts.
The installation of your equipment may be subject to the preparation of an
industrial project for presentation and approval by Industry. Check the regulations
of the country where the installation is taking place.
HIMOINSA S.L. considers it necessary to highlight that the validity of the
information described in this manual may depend on the date it was issued,
since aspects such as technological advances and updates to the regulations in
force, require us to implement modifications without notice.
This manual and the other reference documents form an integral part of the
generator set which has been acquired and must be preserved and protected
against any agents that could damage them. This documentation must
accompany the equipment when it is transferred to another user or to a new
owner.
The manual must always be kept nearby for reference purposes in case of doubt.
Although the information in this manual has been verified in detail, HIMOINSA
waives any liability due to any calligraphic, typographical or transcription errors.
In compliance with EC Directive 85/374 and subsequent amendment 99/34,
HIMOINSA is excluded from any liability as a result of poor installation, improper
use of the machine, and breach of the rules contained in this manual.

INTRODUCTION | PAGE 3
2. SAFETY STANDARDS
Before working on the machine, it is important to carefully read the safety
standards indicated and find out about any local requirements in terms of safety.
In this manual, HIMOINSA S.L. aims to reflect all the potential risks to be avoided;
but it is impossible to consider all of them due to the multiple and varied
circumstances that can generate a risk situation resulting in serious injury, or
even death. For this reason, always operate the equipment with the utmost
responsibility, following safety and prevention measures.
Installation, operation, maintenance and repairs must only be carried out by
authorized and competent personnel, with the owner of the generator set
responsible for ensuring these operations are conducted safely. Parts and
accessories must be replaced if they are not in safe operating conditions.
Different warning signs may appear throughout this manual.

Indicates a hazardous situation which, if not avoided, will

DANGER
result in death or serious injury to the exposed person.
Indicates a hazardous situation which, if not avoided, may
WARNING
result in death or serious injury to the exposed person.
Indicates a hazardous situation which, if not avoided, may
ATTENTION
result in moderate or minor injury to the exposed person.
Taking the contents of this manual as our premise, detailed below are the basic
criteria for the safety of the reader and that of others, which should be carefully
followed.

2.1 GENERAL SAFETY PRECAUTIONS

For your own safety and that of others, pay particular attention to the following
basic safety criteria:
•• Personnel using the equipment must be authorized and qualified. You
must know the safety regulations for the correct use and operation of
the equipment.
•• Always follow the recommendations in this manual for installation,
operation and maintenance of the equipment. Failure to do so may
result in loss of life or serious injury.

SAFETY STANDARDS | PAGE 4

 •• Do not allow unauthorized persons to access the generator set, or
those without proper training.
•• Do not allow people with pacemakers, due to possible
electromagnetic interference on cardiac stimulation devices.
•• Do not approach the generator set while wearing loose clothing or
objects that may be attracted by the air flow or the generator set’s
moving parts.
•• Do not smoke or cause sparks near the generator set or the external
fuel installation.
•• Risk of asphyxiation. Exercise extreme caution with exhaust gases
because depending on the fuel used these gases may contain carbon
monoxide, a colourless, odourless gas which is very dangerous and
harmful if inhaled.
•• Risk of loss of vision. Always use eye protection.
•• Risk of loss of hearing. Always use ear protection.
•• It prohibited to by-pass and/or remove the safety devices as well as
modify the settings of the generator set.
•• It is forbidden to lean on the generator set or leave objects on it.
•• Do not insert objects through the ventilation slots; the equipment
may activate without warning and cause accidents with potential loss
of life.
•• Do not obstruct or impede the passage of air through the ventilation
slots; it may damage the equipment or cause unsafe operation.
•• Risk of electrocution.
•• Risk of fire.
•• Risk of explosion.
•• Use extreme caution when handling the battery/ies
In the case of gensets which are automatically operated, it is also recommended
to:
•• Place a red light in a visible position and turn it on when the genset
is running.
•• Place a warning sign indicating the possibility of the machine
unexpected starting automatically.
•• Place an obligation sign indicating that "All maintenance operations
must be performed with the genset in the LOCKED position".
•• To perform an emergency stop of the genset, press the "emergency
stop" button located on the outer sides of the genset or internally
or adjacent to the protection and control panel, depending on the
genset.
NOTE
In order to locate the place in which some of the components listed below are
installed, go to the Installation Manual.
2.2 SAFETY DURING RECEIPT, STORAGE AND UNPACKING
•• Upon receipt of the generator set check that the material received
corresponds to the delivery order, and that the merchandise is in
perfect condition.
•• When lifting and transporting the generator set, forklifts with
sufficient capacity must be used, following the instructions in the
Installation Manual Section 3.2 Unloading and Handling, and Section
3.3 Transportation. All loose or pivoting parts must be securely
fastened before lifting the equipment.
•• When moving the generator set, and especially during elevation, we
recommend using the points indicated specifically for these functions,
having previously checked the optimal condition of said lifting points.
•• It is strictly forbidden to use other lifting points, located on the
engine, alternator or any other components.
•• If the generator set is damaged for any reason during transport,
storage, and/or assembly, it should not be put into operation without
being checked first by our specialized staff.
•• If you wish to store the genset until it is needed, it is advisable to
use premises which are duly protected from chemical agents that can
damage the machine's components.
•• Unpacking should be carried out with care, avoiding any damage to
the materials during the operation, especially when using levers,
saws or other metallic tools.
SAFETY STANDARDS | PAGE 5
2.3 SAFETY OF THE FUEL GAS SYSTEM
•• The range of gas-powered generator sets uses fuels such as Natural Gas
(NG), Liquefied Petroleum Gas (LPG) in a liquid or gaseous state, Biogas,
and other gases such as associated gas, wellhead gas, mine gas, salt
gas, synthetic gas, etc. All these fuels are volatile and explosive, so they
must be handled with care and extreme caution.
•• Installation, maintenance and fuel storage operations must be carried
out by appropriately qualified personnel, in accordance with the laws
and regulations related to gaseous fuels in the country where such
operations are performed.
•• The characteristics of the gaseous fuels (composition, pressure,
etc.) may vary from one region to another. For this reason, it is
recommended to consult your gas distributor when installing the
gaseous fuel supply system. Use of an improper fuel composition
may cause engine damage and invalidate the warranty. Consult
HIMOINSA S.L. for the accepted composition for the equipment
purchased. To activate the warranty, you need to send the gas
analysis to HIMOINSA S.L., which must be approved before
commissioning the equipment.
•• The fuel system should be inspected frequently (maximum period
between checks is 3 months) and possible losses or fuel leakages
must be corrected immediately.
•• In the event that there are reasonable indications of the presence of
gas, either within the generator set (soundproofed version) or inside
the premises or in the installation area, press the emergency stop
immediately if the equipment is in operation. The following additional
security measures should be taken:
- Electrical switches must not be operated (including not turning off lights
and equipment in operation), nor must sparks or flames be generated,
and immediately action must be taken to close the gas valves and
ventilate the genset or premises.
- After sufficient time for the ventilation of the room and provided that the
smell of gas has disappeared, proceed to locate the leakage using an
approved detector in safe conditions. This operation must be carried out
by an authorized gas equipment installer in accordance with current local
regulations and with the appropriate skills.
- When supplementary lighting is needed for works where gas is
present, safety lamps or flashlights must be used.
2.4 SAFETY DURING INSTALLATION AND COMMISSIONING
•• Installing the Generator Set and its accessories must be performed
by qualified personnel. The installation of the gas supply and its
connection to the equipment may only be carried out by authorized
personnel in accordance with local regulations. In the event of any
difficulty during installation, consult HIMOINSA S.L.'s Technical
Department.
•• It is important to know the emergency procedures related to the
installation to be carried out, as well as positioning a fire extinguisher
near the generator set. Consult the fire department for more
information related to fire prevention.
•• Always wear a protective helmet, safety shoes and gloves, protective
goggles and dry, tight clothes.
•• Do not modify the original protection devices, located on all the
exposed rotary parts, hot surfaces, air intakes, belts and live parts.
•• Do not leave disassembled parts, tools or any other accessories on
the engine, nearby or in premises of the generator set.
•• Never leave flammable liquids or rags soaked with flammable liquids
near the genset, near electrical appliances or electrical installation
parts (including lamps).
•• Take all possible precautions to avoid risk of electrocution; connect
to earth some of the points provided on the generator set and its
accessories, ensuring this earthing is carried out in compliance with
the relevant legislation. For more information, go to the Installation
Manual, Section 5.1 General Information. Earthing.
•• Place a sign stating "IT IS PROHIBITED TO PERFORM OPERATIONS"
on all insulation devices that isolate parts of the installation on which
work must be carried out.
•• Install the necessary safety protection devices on the parts that
complete the installation.
•• If the generator set has a fuel tank, filling must be carried out with
the engine stopped (unless it has an automatic filling system).
•• Insulate all the connections and disconnected wires. Do not leave the
generator set's power terminals uncovered.
•• Check and make sure the electrical connections for power and the
auxiliary services are properly executed.
•• Make sure that the power cables are installed in compliance with
the requirements of all corresponding regulations, as the use
of unsuitable cables may result in serious damage to both the
equipment and people due to the hazardous electrical conditions.
SAFETY STANDARDS | PAGE 6
•• Check that the cyclic direction of the phases matches that of the network. 2.5 SAFETY DURING OPERATION
•• Locate the position of the emergency stop buttons, the fast
•• Do not allow access to the operating area of the generator set by
interceptor fuel valves, switches and any other possible emergency
persons who are unfamiliar with the safety conditions, children or
systems on the installation.
animals.
•• Check the perfect operation of the genset's stop devices. In
•• The person in charge of generator set operations and functioning
particular the following devices (if provided as standard): stop due to
must remain alert and ready to respond to and interpret a situation
overspeeding, low oil pressure, high engine water temperature and
appropriately, and never work while physically or mentally fatigued or
the emergency stop button installed by the user, in general outside
under the influence of medication, drugs or alcohol.
the premises.
•• It is advisable to have a minimum of two people present during
•• Ensure that all exhaust fumes are expelled correctly into the
operations that may pose a health risk, especially due to electrical
atmosphere and from a safe position away from doors, windows and
hazards.
air inlets.
•• Do not touch the generator set, especially cables, copper terminals
•• Change the exhaust system caps, in the event of receiving a genset
and alternator connections, while the genset is running, as they are
with flat caps, and install tilting caps. For more information, go to
live. In the case of an electrical discharge, the first thing to do is
the Installation Manual, Section 7.1 General Information. Exhaust
stop the genset. If this is not possible, try to free the victim from the
System.
source of electrical energy using a non-conductive element. If the
•• Check that the pipes and silencers are installed properly, that they victim is partially or totally unconscious, perform cardiopulmonary
have expansion joints and are protected against accidental impacts. resuscitation (CPR) and seek medical attention immediately.
•• Inspect for leaks in the fuel and oil pipes.
•• In the event your genset is supplied with an engine coolant heater,
connect it to the network via the incorporated plug, as this will allow
faster cold starts to be performed.
•• Locate sources of danger, for example leakage of fuel, lubricating oil,
acid solutions, condensate drip, high pressures and other hazards.
•• Before putting the machine into operation, make sure the generator
set is provided with the right amount of lubricating oil, coolant and
fuel.
•• Identify the position of fire extinguishers and other safety and
emergency devices and learn how to operate them.
•• Check the genset is clean, as well as ensuring the surrounding area
and escape routes are clean and unobstructed. Check for blockages
in the openings as well as the inlet and outlet conduits.
•• Check if there are staff working on other equipment in the area and if
such work is dangerous and affects the operation of the installation. •• Do not touch moving parts until the generator set has completely
•• In the case of installations under environmental or operating stopped.
conditions which are different to those for which the genset •• Check the fuel level in the tank, always ensuring it is at the necessary
was designed, which can be found in the data sheet or on the level for the use which will be given to the generator set.
identification plate of the genset, go to Section 4.4 Derating •• Never connect loads which are above the power range of the
for operating environmental conditions to consider the possible generator set.
correction factors to be applied.

SAFETY STANDARDS | PAGE 7

•• During operation of the generator set, the gas fuel supply should be
continuous and stable, always within the limits set by the combustion
engine (composition, pressure, temperature, etc.).
•• Do not operate the genset if the air filter is not installed.
•• Do not supply power to the battery charger if the batteries are
not properly connected; the electronic devices could be damaged
irreparably. Never disconnect the batteries while the engine is
running.
•• Stop the generator set immediately if any kind of abnormal operation
is detected, such as excessive vibration, leaks, smoke or loss of
output power.
•• Keep doors of the canopy closed, in the case of soundproof gensets,
when they do not need to be open, since the cooling system is
designed for the genset to operate with all doors closed.
•• The exhaust fumes produced by the generator set are dangerous
to health; inhalation can be very harmful due to the concentration
of carbon monoxide. Check that all exhaust fumes are discharged
correctly and that the genset is properly ventilated.
•• Maintain adequate ventilation to ensure your generator set functions
properly. A lack of proper ventilation could cause injury or damage to
property due to excessive heat in the engine.
•• During operation, the genset reaches high temperatures in some
parts of the engine, in ducts and the exhaust, avoid touching them
until they are cold.
•• During operation of the generator set, wear ear protectors to prevent
hearing damage.
•• Labels related to safety must be kept clean and in the places
predetermined by the manufacturer.
•• The fuels and lubricants are flammable, toxic, explosive and
corrosive. We recommend keeping them in their original containers,
never in glass containers, and storing them in protected places. If
you smell fuel, do not start the genset or stop the genset if it is in
operation.
2.6 SAFETY DURING MAINTENANCE
•• Any checks and/or maintenance on the generator set should always
be performed by qualified personnel.
•• Maintenance operations must be carried out with the engine stopped.
When stopping the genset after a period of operation allow it to
cool, taking care not to burn yourself as some components may be
extremely hot when the genset has recently stopped.
•• Do not attempt to open or operate on the gas supply line of the fuel
installation.
•• Before operating on any components of the electrical system,
disconnect the batteries.
•• All the doors on soundproofed gensets are protected against electric
shock by means of equipotential conductors, which must not be
removed under any circumstances. In the event they have to be
removed for cleaning purposes or the replacement of doors, do not
forget to install the same conductors.
•• Before opening the electrical panel, authorized personnel should take
the following precautions:
- Stop the generator set if it is in operation, and put the electrical
panel into the locked position.
- Disconnect any batteries from the generator set.
- Disconnect the mains input to the panel.
•• Periodically check both the tightening and isolation of the
connections.
•• With regards the various operations and/or maintenance procedures
not specifically listed in the user manual, the manufacturer must be
notified for approval.
•• Do not make modifications to the product without the express
knowledge and authorization of our Technical Department.
•• Respect the characteristics recommended by the manufacturer with
regards oil changes and fuel use. Do not use oils or fuels other than
those specified by the manufacturer.
•• Spare parts must correspond to the requirements defined by the
manufacturer. Use only original spare parts. For spare parts only
contact authorized spare parts distributors or workshops which
are part of the HIMOINSA assistance network. To correctly identify
the spare parts required, always specify the data indicated on the
genset's identification plate, the type of engine and/or alternator and
their respective serial numbers.
SAFETY STANDARDS | PAGE 8
•• Periodically check the status of the different components of the
generator set, in particular anti-vibration devices, and the source of
any vibrations and/or increases in noise levels.
•• Periodically check for leakages of water, oil, fuel, and/or battery acid.
•• Do not adjust the engine or other components of the generator set to
obtain performance characteristics which differ to those envisaged by
the manufacturer.
•• Do not work on the fuel tank or the fuel supply conduits when the
engine is hot or running.
•• Wear protective gloves and goggles:
- When using compressed air.
- During the supply of inhibitors or antifreeze products.
- During the replacement or supply of lubricating oil (hot engine oil
may cause burns when being emptied, allow the oil to cool below
60°C).
•• Wear a helmet when working in areas with suspended loads or
equipment at head height.
•• Always wear safety shoes and tight clothing.
•• When working on live parts, always check that your hands and feet
are dry. We recommend using insulating platforms to carry out the
work.
•• Change your clothes immediately if they get wet.
•• Keep smeared rags in containers which are flameproof or suitable for
this purpose.
•• Do not leave rags on the engine.
•• When starting an engine after repairs have been carried out, take
precautions to stop the air intake if there is an excess in revolutions
during the start up.
•• Always keep the engine clean, removing oil, fuel and/or coolant
stains. Do not use a high-pressure washer to clean the engine and
the equipment, as some of the components may be damaged.
•• Never start the engine with the speed control lever disengaged.
•• Do not perform work alone which requires the presence of several
people, especially when work must be performed on moving parts
such as: switches, disconnectors, fuses and/or other live devices.
2.6.1. ENGINE COOLING CIRCUIT
•• Never add coolant to a hot engine; first let the engine cool.
•• Periodically check the coolant level and, if necessary, top up to the
correct level using only liquid recommended in the engine's use and
maintenance manual.
•• Remove the radiator cap slowly. Typically, the cooling circuits are
under pressure, therefore hot liquid could be released violently if the
pressure is discharged very quickly.
•• In the event you want to remove the radiator fluid, there is an
extraction valve available which has been designed for this use.
•• Never use sea water or other corrosive or electrolytic products as a
coolant.
•• Periodically check the tension and state of wear of the pump/fan
belts.
2.6.2. LUBRICATION CIRCUIT
•• The crankcase should always have a minimum level of oil, which must
be commensurate to the operation to be performed by the genset.
It is recommended to periodically check this level using the engine
dipstick marked with the corresponding identification sticker.
•• If the oil is extracted for maintenance purposes, when it is replaced,
fill the oil tray following the instructions in the engine use and
maintenance manual, meeting the quality requirements of the
combustion engine.
•• Do not smoke or light fires while supplying the oil.
2.6.3. FUEL CIRCUIT
•• Only use the type of fuel specified in the technical specifications of
the generator set, respecting the gas composition recommended by
HIMOINSA and by the corresponding engine manufacturer.
•• Possibility of using two types of gaseous fuels. This is the case for
gas engines with a "Dual Fuel" configuration, suitable for the supply
of Natural Gas or LPG. For these cases, the engine operating manual
details the technical specifications for the operation of Dual Fuel
systems.
SAFETY STANDARDS | PAGE 9
 •• Maintenance and possible repairs of the gas system included within
the genset, such as the design, installation, maintenance and
replacement of the fuel supply line to the genset, must be carried out
by qualified specialists.
•• Gaseous fuels are highly flammable substances and can cause fires
and explosions. Use extreme caution in the vicinity of the genset,
with the gas installation and during fuel replacement, remembering
that it strictly forbidden to smoke, start fires and cause sparks.
•• When filling the tank, in the case of using LPG, make sure no dirt or
moisture enters the fuel system.
•• Always use the recommended fuels. Fuel of inferior quality or with
a composition differing to that specified may damage the engine,
affecting performance and service life.
•• When interruptions occur to work in progress, appropriate safety
measures must be taken to ensure the absence of gas and prevent
manipulation by third parties if possible locking the corresponding
stop valves, placing caps, etc.
•• Modifications or extensions to the installation must not be performed
without first closing the supply, unless appropriate techniques are
used to operate while under load.
•• In the case of carrying out repairs on the installation, it is necessary,
before reopening the fuel supply, to conduct a check of the sealing
of the repaired section, the operating pressure, checking the sealed
joints of the repaired section to the existing installation using
appropriate methods (gas detector, soapy water, etc.).
•• Any operation that first requires the venting of gas within the system,
must be done in such a way that there is no possibility of an air-gas
mixture within the flammability limits, both inside the generator set,
as well as inside the premises where the installation is located.
2.6.4. LIQUID COLLECTION TRAYS
•• Possible spillage of fluids within the genset (fuel, oil, coolant or water)
are caught in the collection vessels at the base of the container.
•• It is advisable to regularly make sure there is no fluid in the collection
vessels. If necessary, drain the vessels using the corresponding
drainage holes, in the corners of the genset.
•• Never empty the liquid collection vessels onto the ground; do so into
a suitable vessel.
2.6.5. EXHAUST CIRCUIT
•• Visually check the exhaust circuit, if any gas leakage is detected,
conduct repairs immediately, because inhalation is very harmful to
health, as well as being a potential source of fire.
•• Warning: very hot surfaces. Installation parts which are pre-
assembled at the factory are protected from accidental impacts.
The installer must insulate and/or protect accessory parts, the gas
evacuation piping at the premises, the silencer supplied separately,
etc.
•• Drain the exhaust piping through the condensate discharge points, in
the event they are incorporated.
2.6.6. ELECTRIC START SYSTEM
•• To prevent the engine's automatic start system from activating
while work is being carried out on the engine, use the disconnector
installed for this purpose, if included, or disconnect the negative
cable (-) of the battery(s) before working on the engine.
•• Keep connections tight and make sure the cable insulation is
satisfactory.
•• To prevent the danger of arcing, we recommend always connecting
the positive terminal to the battery first, then the negative terminal
(usually earth).
2.6.7. SYNCHRONOUS GENERATOR
•• Do not carry out interventions with the genset in operation. Before
intervening, put the genset into the LOCK position.
•• Ensure the air inlets ventilating the generator are kept clean and, with
some models, lubricate the bearings. In particular, check that the
tightness and position of the electrical connections are correct.
2.6.8. CONTROL PANEL
•• Before working on the control panel, disconnect the power supply and
the battery/batteries, putting the genset into the LOCK position.
•• The electrical control panels, like all electrical equipment, have
moisture and dust. Check the correct operation of the anti-
condensation heaters, where provided, and clean the air inlets used
for ventilation.
SAFETY STANDARDS | PAGE 10
 •• Periodically check that the pins securing the electrical connections •• Risk of explosion. Batteries emit explosive gases. Always disconnect
are well tightened. the negative cable from the battery first to avoid sparks. Failure to do
so can cause death or serious injury.
•• Risk of explosion. Do not throw a battery into fire; they are explosive.
2.6.9. BATTERIES The electrolyte is corrosive and can cause burns and/or blindness.
If the electrolyte comes into contact with eyes, flush them with water
•• The batteries incorporated in the generator set are maintenance free.
for at least 10 minutes and contact a doctor immediately.
•• Periodically check the connections of the battery terminals to ensure
•• Environmental risk. Always dispose of your batteries at an authorized
they are clean, tight and protected from the weather.
recycling centre in accordance with local regulations. If you do not,
•• Never invert the positive and negative terminals of the batteries there is a risk of environmental damage, death or serious injury.
when connecting them. An inversion may result in serious damage to
the electrical equipment. Follow the wiring diagram supplied by the
manufacturer.
•• To disconnect the batteries use the disconnector, in the event it is 2.7 ENVIRONMENTAL SAFETY
included, as it is installed for this purpose or disconnect the negative
cable (-). •• Do not start the genset in confined areas without installing an
exhaust pipe which vents fumes outside. Exhaust gases are harmful
•• Use extreme caution when replacing the batteries. Always wear and can be lethal.
protective clothing, gloves and goggles as the electrolyte inside the
batteries is diluted sulphuric acid which is harmful if it comes into •• Observe the rules and regulations concerning acoustic installations.
contact with skin or eyes. In the event it comes into contact with skin, •• Never run the engine without an air filter or without an exhaust.
remove all contaminated clothing and wash the affected areas with •• Replace the engine's exhaust pipe and/or silencer if the noise level
soap and water. In the event it comes into contact with eyes, rinse emitted is higher than that permitted by corresponding legislation.
with water for 15 minutes and seek immediate medical assistance.
•• Maintenance (oil changes, cleaning the fuel tank, cleaning the
•• In some countries the batteries are considered hazardous waste. Use radiator, washes, battery changes, etc.), storage and waste disposal
appropriate containers or contact any organisations responsible for must be carried out according to the regulations in the country of
the collection of this waste. use.
•• Due to the high flammability of the electrolyte gases, avoid the
presence of sparks or flames. Do not smoke around batteries.
Precautions to be taken with batteries
•• Do not wear jewellery while working on this equipment. If you do so
you will be at risk of death or serious injury
•• Risk of explosion. Batteries emit flammable gases while being
recharged. Keep any ignition source away from them. Wear eye
protection while handling batteries. If you don't, you will be at risk of
death or serious injury

SAFETY STANDARDS | PAGE 11

2.8 SAFETY AND INFORMATION STICKERS Drawing Location Information

Indicates that it is compulsory to read the

The generator set has several safety and information stickers affixed to it in Located in the engine instruction manuals before any kind of
order to attract the attention of the operator or technician regarding potential operation
dangers and with explanations on how to act safely.
These are the points where the genset
Next to the branch circuits of
A brief explanation of the location and information about each one is given below: is protected from possible electrical
the earth protection devices
discharges
Drawing Location Information
Output terminals for connecting the load,
Next to the circuit breakers
corresponding to each of the phases and
Located near the connections protecting the genset
Warn of danger if a foreign object inter- neutral
between the alternator and the
feres with the genset's timing belts or any
engine. Where there are timing Located on the outer sides of
moving elements connected to them Indicates the position of the emergency
belts or transmission shafts the genset, inside or adjacent
stop button that allows the equipment to
to the protection and control
be simultaneously stopped
panel.
Indicate which areas not to touch while
Located on parts of the genset
the genset is running or shortly after it Located in the protection and Warn of danger due to the presence of
that heat up during operation
has stopped control panel voltage

Located on the canopy/chas-

Warn that caution must be taken when Informs about the danger of explosion
sis of the generator set
Located on the coolant filler opening the cap; the liquid is hot and can
cap be discharged under pressure causing
burns
Always located next to the Reports that it is prohibited to manipulate
motorised circuit breaker the genset with the switch connected

Located on the lifting points
and next to the lifting hook
Located next to the fuel cap.
Depending on the model, it will
be on the bedplate or next to
the engine
Indicates the point from which the genset
must be lifted in order to move it
Indicates the range of supply pressure
permitted
Positioned on the protection
and control panel, above the
motorised circuit breaker
Located in the protection and
control panel
Warning and reminder about replacing the
exhaust system covers before starting
the genset
Reports that it is necessary to check that
there is a sufficient level of fuel in the
tank before each start

On either side of the bedplate
skids
Indicates the recommended area for Reports that, when the doors have been
Located inside the container
transporting the genset by forklift truck opened, to close them it is necessary to
doors, next to the locking pins
loosen the locking pin

Located next to the oil dipstick

Reports the location of the oil dipstick Inform and warn that the container doors
and oil filler cap Located on the exhaust
must be kept closed while the genset is
silencers
in operation

SAFETY STANDARDS | PAGE 12

Change any stickers which are missing or illegible.

NOTE
It is possible that some of the stickers indicated are not necessary for your
generator set model, and are not included with the genset.

SAFETY STANDARDS | PAGE 13

3. GENERIC DESCRIPTION
The aim of the gas generator set is to provide continuous power generation which
is more efficient, economical and clean, when compared to other generation
systems. The use of gas as fuel saves on fuel costs, means a reduction in noise
emissions and polluting gases, together with more economical maintenance
thanks to the use of stronger engines and a longer use of the oil employed.
The generator set is driven by engines that consume gas for combustion. These
are 2- or 4-stroke engines, with spark plug injection, natural aspiration,
turbocharged and/or post-cooled, with the cylinders arranged in line or in a V
(depending on the engine model), and water-cooled. The engines used are fitted
with all the accessories that provide high reliability in the power supply.
To generate the electricity demanded, alternators are used with a horizontal axis,
synchronous, brushless, self-excited and self-regulated through automatic voltage
regulators.
The engine and alternator are coupled and mounted on the supporting bedplate
or frame, formed by a thin sheet structure made of high strength steel, which in
turn incorporates the battery system with its corresponding clamping fittings.
This coupling between the generator set and the bedplate includes elastic
supports (silentblocks) designed to reduce engine vibration transmitted to the
foundations on which the generator set is installed.
The fuel supply will be carried out through the connection of the HIMOINSA
generator set gas train to the gas connection of the property. In all HIMOINSA
generator sets, a threaded female connection is available (variable diameter,
depending on the generator set model and specified in the data sheet for the
generator set) located on the side of the genset canopy, in the case of
soundproofed gensets, or, on a vertical plate, welded to the chassis for open-skid
version gensets. Therefore, the customer must provide a length of flexible tubing
with a threaded male connection (variable diameter, depending on the generator
set model and specified in the data sheet for the generator set) for coupling with
the gas train. This is a “Plug and Play” fuel supply system.
The engine exhaust can be muffled using a high attenuation silencer that
guarantees an appropriate reduction in noise emission levels.
The genset cooling package consists of a radiator, a large fan and a thermostat.
For soundproofed static gensets, the canopy is made of sheet steel of suitable
thickness, duly treated to provide a perfect finish. Inside it is coated with a fire-

OVERVIEW | PAGE 14
retardant sound-absorbing material classified as a M-0 material. In the air inlet Regarding gensets for use on land, according to the intended use, there are two
and outlet areas, the canopy is provided with corresponding ducts, designed to envisaged types:
channel air without the logical reverberations occurring in a forced air conduction. •• Static gensets (fixed installations)
The door locks are provided with a key to ensure non-authorised persons cannot •• Portable gensets (mobile installations)
operate the equipment, even from the control part of the genset. These keys are
universal, with the same key valid for all the doors. The two versions in turn can be subdivided into a wide range of models according
to the operating modes and requirements:
The generator set canopy incorporates, on all gaskets, an external seal made
•• Manually operated gensets
from a high-density polyurethane-based silicone, which minimises water ingress
•• Automatically operated gensets
inside the generator.
•• Continuity gensets

NOTE This manual provides general information for the use and maintenance of
If the user removes this seal to carry out any maintenance or repairs on the HIMOINSA gas generator sets with manual and automatic operation.
generator outside or within the established warranty period, HIMOINSA accepts
no responsibility for any damage that might be related to water ingress inside
the generator set.
3.1 COMPOSITION OF THE GENERATOR SET
These gensets may include a control and/or operation panel, consisting of a
control unit and a series of buttons, and a protection panel with a circuit breaker, Each generator set looks different due to the various sizes and configurations of
among other components. each of the main components.
The generator sets are used for two main types of service: A open-skid genset usually consists of:
•• Continuous service gensets. The predominant application of gas - Combustion engine, including the following equipment:
generator sets is continuous generation: electricity production 24
hours a day, 7 days a week (24/7). This application is common in •• Ignition system.
locations where there are no other sources of electricity or where it is •• Air/gaseous fuel mixer.
deficient. •• Control system for engine speed/power. The main equipment is the
•• Emergency service gensets. Furthermore, it is also possible to throttle valve or commonly just called the "throttle".
use the gas generator set for emergency applications: applications •• Anti-detonation system or commonly called "anti-knocking" (non-
where the gas generator set is not the main power source. standard, according to manufacturer and engine model).
Examples: switching with main source (the mains in most cases),
•• Emission measurement system: if incorporated, it will include a
synchronization with the primary source to reduce peak consumption,
lambda sensor reading in the exhaust fumes, or the pressure and
etc.
temperature reading of the exhaust fumes.
According to the assigned destination, gensets are subdivided into:
•• Gensets for use on land
•• Gensets for use at sea

OVERVIEW | PAGE 15
 10 2 7 6 1 5 4 3 With the soundproofed static generator set, in addition to the parts described for
the open-skid generator set, the following components are found in the canopy:

7 1 9 3 7 7 10 8 4

9 8

1. Gas combustion engine 6. Turbocharger (*)

2. Alternator 7. Exhaust outlet
6 2 5
3. Radiator 8. Gas supply inlet
4. Fan 9. Gas train (See section 3.2) 1. Window for observation of the control panel 6. Emergency stop button
5. Dry air filter 10. Control panel and power/power cables output panel 2. Power cables output (back of genset) 7. Air intake grilles (more in back of genset)
3. Lifting point 8. Air outlet grilles (top view and profile of genset)
* Depending on the engine model
4. Exhaust outlet tilting cap 9. Key locks
5. Gas supply inlet 10. Radiator filler caps (Top view of genset) (*)
18 17 16 10
* Depending on the genset model includes one or more caps.

A Rental generator set, in addition to the parts described for the open-skid or
soundproofed static generator set, incorporates a separate chassis housing LPG
storage tanks:

13 12 11 15 13 14

11. Starter motor 15. Anti-vibration devices

12. Starter batteries 16. Carburettor or Mixer
13. Lifting points 17. Secondary pressure regulator (or zero pressure regulator) 1. Fuel intake 5. Insulated chassis

14. Bedplate 18. Intercooler (*) 2. Relief valves 6. Lifting point

* Depending on the engine model 3. LPG tanks (3 units) 7. Side openings for tank maintenance
4. Gas presence sensors 8. Ventilation grids

OVERVIEW | PAGE 16
3.2 GAS TRAIN
As a standard scope of supply, all HIMOINSA gas generator sets include a series
of devices for gas control, measurement and safety, collectively referred to as
the "gas train". The "Gas Train" allows gas to travel from the inlet valve of the
generator set (whether or not there is a storage tank) to the engine, without the
need to include additional elements, ensuring safe operation of the equipment,
no gas leakage and compliance with local regulations.
On the one hand, the "gas train" inlet corresponds to the fuel inlet on the
generator set, formed by a threaded female connection (variable diameter
depending on the version) which is easily accessible for both construction
versions: open or soundproofed (in the latter case it is located on the external
part of the canopy or container, depending on the model). Note that the last
section of the connection between the "gas train" inlet and the customer's gas
installation, must be carried out with flexible hose (preferably stainless steel),
and must never be carried out using a rigid pipe.
On the other hand, the "gas train" outlet is connected directly to the engine,
with the inlet pressure of the generator set having been adjusted to the
pressure of the working gas in the engine.
Standard gas train equipment in HIMOINSA generator sets:
1. Manual ball valve: manual opening/closing of the fuel supply.
2. Gas filter: filtering of particles which are less than 50 microns in size (standard
filter, for other filtering levels consult the HIMOINSA Technical Department).
3. Primary pressure regulator - pressure stabiliser: decrease and stabilisation of
the gas inlet pressure in the generator set. The pressure is regulated to the
pressure value of the secondary pressure regulator. The usual maximum inlet
pressure value in the genset is 500 mbar (check for each model). This equipment
is supplied as standard for the majority of HIMOINSA machines (see observation
for the equipment described below). The minimum inlet pressure must be at
least 30 mbar. For lower pressures first consult the HIMOINSA technical
department.
4. Secondary pressure regulator: decrease in gas pressure to atmospheric
pressure (1 bar of absolute pressure, or equivalently 0 bar of gauge or relative
pressure). This regulator is also called a zero-pressure regulator. The inclusion of
this regulator is mandatory and necessary to ensure optimal performance in all
gas generator sets unless the engine in question is supplied under high pressure.
In addition, with generator set models designed to be supplied at very low
pressure <30 mbar, it is possible that there is no primary pressure regulator, it
being necessary in this case that the genset inlet pressure is equal to or less
than the maximum inlet pressure of the regulator. The usual maximum inlet
pressure value in the secondary pressure regulator is 50 mbar (check for each
model).
5. Double solenoid valve: automatic opening/closing of the fuel supply. Using
double solenoid valves increases the safety of the installation with respect to the
use of single solenoid valves. Furthermore, there is no need for external venting of
the gap between two single solenoid valves, which simplifies and reduces costs for
installation design.
6. Low pressure safety switch: device that detects gas pressure which is lower
than the minimum gas pressure required for each of the gas generator sets.
Adjustable.
7. Automatic safety system for checking solenoid valve tightness: during the
generator set startup sequence the process for checking solenoid valve tightness
is programmed automatically, which involves injecting pressurized air between
the double solenoid valves, so that if this is not able to close tight with absolute
safety, this checking system sends an alarm signal indicating fuel leakage to the
genset control unit, the genset will not be able to start until the fuel leakage is
eliminated. Consequently, the installation of this device leads to an increase in
the safety of gas generator set. This device can only be installed in gas generator
sets powered by 24 VDC batteries or higher.
8. Pressure gauges: gas generator sets models which are fitted with primary and
secondary pressure regulators, have two pressure gauges installed, one to
measure the generator set inlet pressure (gas train inlet pressure) and another
to measure the gas train outlet pressure. On the other hand, in the case that the
gas generator set only has a secondary pressure regulator, only a pressure gauge
will be installed which will measure the gas inlet pressure to the generator set.
NOTE
Contact the HIMOINSA Technical Department if additional gas regulation,
measurement or safety equipment is required, such as: gas compressor, high
pressure switch, high pressure regulator, flame arrestor (mainly for biogas
plants), vent valve, gas leak detector for inside the canopy or container, among
others.
OVERVIEW | PAGE 17
 DANGER 2. Gas train WITH automatic safety system for checking solenoid valve tightness:
gas generator set with a battery voltage of 24 VDC.
HIMOINSA gas generator sets have a start / stop sequence which is specifically
developed to increase safety when using the equipment and to prevent possible
explosions due to the accumulation of gas inside the engine or the intake or
exhaust manifolds. The modification of the gas train or the replacement/
change/modification of any of its elements without the prior knowledge of
HIMOINSA poses a risk to the safety of people.
In order to identify the gas train equipment, two different images are highlighted:
1. Gas train WITHOUT automatic safety system for checking solenoid valve
tightness: gas generator set with a battery voltage of 12 VDC.

8 7 6 5 4

7. Low pressure gauge (**) 8. Automatic system for checking solenoid valve tightness
* Secondary pressure regulator installed in the engine, upstream of the mixer
** Optional: High pressure gauge

6 7 5 1 4 2 3

1. Manual ball valve 4. Gas filter

2. Inlet pressure gauge 5. Primary pressure regulator (*)
3. Outlet pressure gauge 6. Double solenoid valve

OVERVIEW | PAGE 18
3.3 IDENTIFICATION PLATE

Generator sets, as well as their components, incorporate identification plates

that provide the following information:
GE model
Construction
version
Company logo Frequency Factory
Voltage address
Type of electrical
panel

Main data of the

generator set

Internal
barcode

CE marking

In most cases, the identification plate will be located on the electrical panel.

OVERVIEW | PAGE 19
4. OPERATING CONDITIONS

4.1 WARNINGS IN THE CASE OF MISUSE

The generator set which HIMOINSA has supplied is designed for the production
of electrical energy according to the environmental and operating conditions and
limits indicated or agreed in the contract. Any modifications to such conditions
and limits must be communicated directly to the factory or via the organization of
authorized repair centres to obtain optimum performance and, if necessary, to
make changes and/or new calibrations to the genset.
The generator set is a machine which converts the potential thermal energy
contained in the fuel into electrical power; and is intended to supply distribution
installations which must be carried out by experts pursuant to current regulations.
While the power levels available may be lower than those of a public supply
system, the danger posed by the electrical energy is the same. The generator set
is a production control unit which, in addition to the risks of an electrical nature
that are similar to those of the power supply from the public grid, also presents
dangers arising from the presence of fuel substances (fuel itself or lubricating
oils), rotating parts and waste by-products (exhaust fumes and cooling and
irradiation heat).
All the electric power values for HIMOINSA gas generator sets are declared
according to the particular fuel composition. In the event the gaseous fuel used
by the customer does not comply with the gas composition limits recommended
by the motorist, the HIMOINSA Technical Department will assess the compatibility
of the fuel with the engine in question, and if approved, will determine whether
there is derating present to the mechanical power of the engine. Therefore,
HIMOINSA recommends that the customer has the composition of gaseous fuel
to be used available to confirm the actual electric power of the genset.

OPERATING CONDITIONS | PAGE 20

NOTE
In the case of having to apply a derating for fuel composition and an additional
derating for environmental conditions other than those indicated, we must
consider both factors. In this case, the HIMOINSA Technical Department will
calculate the net electrical power under these conditions.
Any other use that has not been previously agreed with HIMOINSA should be
considered as improper and as such is not acceptable.
4.2 STANDARD REFERENCE ENVIRONMENTAL CONDITIONS
The engine used in HIMOINSA generator sets are engines, which as standard,
can only be supplied by a single gaseous fuel. However, in the case of some
models of HIMOINSA generator sets, it is possible to operate them with a BI-
FUEL configuration, it being possible to supply the same generator set with two
gaseous fuels: Natural Gas and LPG or Natural Gas and Biogas.
If the generator set is configured for BI-FUEL applications, it is necessary to
indicate the type of fuel to be used by means of a fuel selector, which is located
in the electronic control unit. This selector can have two or three positions,
depending on the version.

4.2.1 COMBUSTION ENGINE

With regards the power levels of the internal combustion engines, for stationary Position A: to operate with LPG from the internal tanks (RENTAL LPG equip-
applications, refer to the following environmental conditions in accordance with ment only)
Standard ISO 3046/1: Position B: to operate with LPG from an external tank
•• Ambient temperature 25°C Position C: to operate with Natural Gas (if it is a long period of operation)
•• Ambient pressure 1000 mbar (750 mm/Hg) There are other gaseous fuels such as syngas, CSG, shale gas, etc. To use these
•• Relative humidity 30% fuels please first contact the HIMOINSA technical department.

4.2.2 SYNCHRONOUS GENERATOR NOTE

If you wish to work on BI-FUEL applications, please consult the HIMOINSA
•• The reference environmental conditions for alternators, for stationary Technical Department.
applications according to standards IEC 34-I, ISO 8528-3 and CEI 2-3
are as follows:
•• Ambient temperature 40°C (30°C according to NEMA)
•• Altitude 1000 masl (674 mm/Hg) 4.3.1 GASEOUS FUEL QUALITY

Gaseous fuels are formed by the mixture of gaseous hydrocarbons such as

4.3 FUEL SELECTION CONSIDERATIONS methane (CH4), propane (C3H8), butane (C4H10) or ethane (C2H6), with other
gaseous elements such as nitrogen (N2) and oxygen (O2), vaporised water and
HIMOINSA generator sets can be powered by three types of gaseous fuel various contaminants such as sulphur (S) and/or hydrogen sulphide (H2S), as
according to the version: well as carbon dioxide (CO2) and siloxanes in the case of biogas.
•• Natural Gas The quality of the gaseous fuel is directly determined by its composition, since
•• LPG (Liquefied Petroleum Gas) small variations are allowed within one type of gaseous fuel because its
•• Biogas composition varies depending on the origin of the fuel. These small differences
in fuel components affect the amount of energy per unit volume of fuel, the

OPERATING CONDITIONS | PAGE 21

amount of contaminants in it and the gas compression ratio, etc., which in turn
may influence the operation of the generator set.
The parameters that define the quality of the gaseous fuels are:
•• Molar composition.
•• Gross Calorific Value (GCV): this is the heat given off during the
complete combustion of a unit of gas considering the water
condensation energy, in kJ/Nm3.
•• Net Calorific Value (NCV): this is the combustion, i.e., that produced
in the complete combustion of a unit volume of gas regardless
of the condensation energy of water and other processes of little
importance, in kJ/Nm3.
•• Pressure at the outlet of the supply connection stopcock, information
provided by the natural gas supplier.
•• Relative density (ρ): this is the gas density used divided by the dry
air density in a standardised composition under the same specific
pressure and temperature conditions.
•• Wobbe Index (WI): This indicates the interchangeability between
gases to ensure satisfactory combustion of the gas, in MJ/m3. This
can be obtained by the following equation:
Depending on the Wobbe index, standard UNE 60002:1995 classifies gaseous
fuels into: first family (22.4 MJ/m3 ≤ Ws ≤ 24.8 MJ/m3), second family (39.1 MJ/
m3 ≤ Ws ≤ 54.7 MJ/m3) and third family (72.7 MJ/m3 ≤ Ws ≤ 87.3 MJ/m3).
In addition to the composition, we must take into account temperature, pressure
and humidity, since the properties of gaseous fuels are affected by varying
environmental conditions.
It is therefore important to check the quality of the fuel used for the established
operation of the generator set, always meeting the requirements of the
incorporated engine. This information may be found in the documentation
supplied with the combustion engine.
In the event a gaseous fuel is used which differs to that specified in the operating
requirements of the combustion engine composition, derating must be applied to
correct the output power values.
4.3.2 NATURAL GAS
Natural gas consists of a mixture of hydrocarbons whose main component is
methane with other light hydrocarbons such as ethane, propane, butane or
pentane (C5H12) to a much lesser extent. Its chemical composition, however,
varies considerably according to its source, as it is commonly associated with
other molecules or inert gases such as carbon dioxide (CO2) or nitrogen.
Natural gas is, at standard temperature and ambient pressure, gaseous and has
a relative density which is less than that of air, which means that it dissipates
into the atmosphere in the case of leakage, reducing the risk of explosion.
The use of natural gas as a fuel does not require, in most cases, storage as the
local mains supply of gas is used, requiring no pre-use preparation, such as
heating, pulverizing and pumping.
The combustion of this gaseous fuel, in an appropriate proportion with air, burns
without the release of ash, carbon dioxide or other pollutants, complying with the
highest international standards without the need for the treatment of fumes,
recognised as the cleanest combustion among traditional industrial fuels.
According to UNE 60002:1995 natural gas is included in the second family, with
a Wobbe index of between 39.1 MJ/m3 and 54.7 MJ/m3.
4.3.3 LIQUEFIED PETROLEUM GAS
Liquefied petroleum gas (LPG) refers to hydrocarbon mixtures consisting mainly
of propane and butane, along with its derivative compounds being essentially
free of sulphur and other substances such as metals. They are gaseous at
atmospheric temperature and pressure, and have the ability to turn into a liquid
state at relatively low pressures, a property that is used for storage and
transportation in pressure containers.
Liquefied petroleum gases have a higher heating value to other gaseous fuels
and consequently can obtain the same amount of total power with less fuel. They
also have a density that is about 1.8 times greater than air, so a leak can be very
dangerous because the vapours tend to be concentrated in low areas and where
there is greater risk of finding flashpoints.
The use of liquefied petroleum gas as fuel requires storage tanks subjected to
high pressures to maintain the fuel in a liquid state, taking special consideration
of its use and location in accordance with the applicable national standards.
OPERATING CONDITIONS | PAGE 22
The generator set operates with fuel in a gaseous state, therefore, although this
fuel is stored in a tank in a liquid state, it is important to note that must be
supplied to the genset inlet in a gaseous state.
In accordance with standard UNE 60002:1995 liquefied petroleum gas is
included in 72.9 MJ/m3 and 87.3 MJ/m3.
4.3.4 BIOGAS
Biogas is a gaseous fuel obtained as a result of the anaerobic fermentation of
organic material. Its composition is mainly formed of methane (typically 40-60%),
along with carbon dioxide and other gases in lower concentrations such as
hydrogen, nitrogen, oxygen and hydrogen sulphide. The composition is variable,
depending on the composition of the starting material and the fermentation
conditions.
The characteristic properties of biogas as a fuel are very similar to those of
natural gas, but appropriate purification will be necessary to ensure they are
below the maximum contaminant levels allowed for natural gas, avoiding possible
damage to the combustion engine.
4.4 DERATING FOR OPERATING ENVIRONMENTAL CONDITIONS
In the event of environmental conditions of installation and operation, other than
those indicated in the previous section, it will be necessary to carry out
appropriate power losses or "derating", both for the engine and the alternator
which it is coupled to, and therefore the electrical power supplied by the
assembly.
When making a quote request, the User/Customer should clearly state the actual
environmental conditions in which the generator set will operate. Since derating
and declassification must be fixed at the time of drawing up the contract, so that
both the engine and the generator are dimensioned properly.
In particular, the User/Customer must communicate the following environmental
conditions under which the generator set will operate:
1. The lower and upper ambient temperature limits.
2. The altitude above sea level or, preferably, the minimum and maximum
barometric pressure values in the installation site; in the case of mobile gensets,
the minimum and maximum limits of altitude above sea level.
3. Humidity values in relation to the temperature and pressure of the installation
site, with special attention to the value of relative humidity at the maximum
temperature.
4. Any other special environmental conditions that may require special solutions
or shorter maintenance cycles, such as:
•• Dusty and/or sandy environments
•• Marine type environments
•• Environments with potential chemical pollution
•• Environments with radiation
•• Operating conditions in the presence of large vibrations (e.g. areas
subject to earthquakes or other external vibrations generated by
nearby machines)
NOTE
When the actual conditions are not come specified in the contractual phase, the
power of the genset is understood to refer to standard conditions for the gas
engine, as established.
If the actual environmental conditions change in the future, it will be necessary to
contact the HIMOINSA organization to calculate the new power losses and to
make the necessary calibrations.
For gas engines, this derating is determined by the corresponding engine
manufacturers, to find out this information contact HIMOINSA's Technical
Department or request it from your usual dealer.
Derating the alternator is less important than the combustion engine; as such
the derating of the generator set generally resembles the derating of the engine.
OPERATING CONDITIONS | PAGE 23
Purely for information purposes, Table 1 is presented for the determination of the EXAMPLE: SIZING OF THE ALTERNATOR
derating of the alternators, by applying reduction coefficients depending on the
A generator set of 64 kW (80 kVA) under standard conditions with the engine at
ambient temperature and altitude.
25°C, 100 masl and 30% relative humidity.

Table 1 The genset consists of:

Alternator power reduction coefficients according to the various environmental conditions •• A supercharged engine of 72 kW at 25°C, 100 masl and 30% RH.
Ambient temperature (°C) 30 35 40 45 50 55 60 •• An alternator of 80 kVA delivered at 40°C and 1000 masl; with a
Reduction coefficient K1 1.05 1.03 1.00 0.96 0.92 0.88 0.84
performance of 89%.

Altitude (masl) 1000 1500 2000 2500 3000 3500 4000

You want to check the maximum power that the genset can deliver at 1500 masl
and a temperature of 45°C.
Reduction coefficient K2 1.00 0.97 0.95 0.92 0.89 0.86 0.83
The engine derating coefficient indicated by the manufacturer of the engine is
The coefficients K1 and K2 shown in Table 1 refer to alternators, which are air- 0.75 for the environmental conditions required by the genset. Therefore, engine
cooled, self-ventilated and with protection level IP21. Both should be applied to power, under the specified conditions, will be:
the rated power of the generator to obtain power under environmental conditions
Pengine= 0.75 · 72 = 54 kW
which differ to standard conditions, as shown in the following example:
Given the performance of the alternator, the power of the genset is:
Pgenset = 54 · 0.89 = 48 kW
Finally, it is necessary to check that the alternator is appropriate for the power
that the genset is able to deliver, which has just been calculated.
To do this, it is necessary to obtain the alternator derating via the reduction
coefficients K1 and K2 shown in Table 1 above or otherwise as directed by the
manufacturer of the alternator.
Therefore, for the environmental conditions of the genset (45°C and 1500 masl)
the following reduction of apparent maximum reference power is obtained for the
alternator:
Salternator = K1 · K2 · Sref = 0.96 · 0.97 · 80 = 74.4 kVA
Therefore, the active power for a power factor of 0.8 will be:
Palternator= 74.4 · 0.8 = 59.2 kW
It is evident that the alternator is oversized with respect to the power that the
genset can deliver (48 kW) under the environmental operating conditions
required.

NOTE
For greater precision, refer to the manufacturer's documentation.

OPERATING CONDITIONS | PAGE 24

4.5 OPERATING LIMITS
The User/Customer should communicate, during the quote request phase, all
the operating conditions that may affect the operation of the generator set. In
addition to the environmental conditions described in the previous paragraph,
special attention should be given to the characteristics of the loads to be
connected, the power, the voltage and the power factor. It is necessary to
determine and indicate the load connection sequence with a great deal of
accuracy.
4.5.1 POWER
The generator set power is the active power (expressed in kW) delivered via the
generator's terminals, at the voltage and frequency and under the environmental
conditions established.
According to ISO 8528-1, the various power outputs of the generator sets are
defined as follows:
CONTINUOUS POWER (COP)
This is the maximum power available for use under constant loads for an
unlimited number of hours per year between the maintenance intervals prescribed
by the manufacturer and under the established environmental conditions.
PRIME POWER (PRP)
This is the maximum power available for use under variable loads for an unlimited
number of hours per year between the maintenance intervals prescribed by the
manufacturer and under the established environmental conditions. The average
consumable power over a period of 24 hours must not exceed 70% of the PRP.
EMERGENCY STANDBY POWER (ESP)
This is the maximum power available for use under variable loads in the event of
a network power outage or under test conditions for a limited number of 200
hours per year between the maintenance intervals prescribed by the manufacturer
and under the established environmental conditions. The average consumable
power over a period of 24 hours must not exceed 70% of the ESP.
NOTE
The performance levels listed, with a tolerance of ±3%, are net of the flywheel
and can be obtained after 50 hours of operation.
4.5.2 FREQUENCY
HIMOINSA gas generator sets are intended to operate at 1500 r.p.m. and/or
1800 r.p.m., with a frequency of 50 Hz and/or 60 Hz respectively.
There are special cases where the engine can work at other speeds, in which
case you will receive additional documentation in this regard.
All gas engines supplied in HIMOINSA gas generator sets are equipped with an
electronic regulator.
The frequency value response of the gas generator sets will be measured
according to the technical specifications described in standard ISO 8528-5, in
the same way as the procedure with diesel generator sets.
4.5.3 VOLTAGE
The generator voltage regulator is electronic with features that control the voltage
at the terminals.
The voltage value response of the gas generator sets will be measured according
to the technical specifications described in standard ISO 8528-5, in the same
way as the procedure with diesel generator sets.
4.5.4 POWER FACTOR (COS φ)
The power factor is defined as the ratio between the active power (kW) and
apparent power (kVA), describing the amount of electricity consumed which has
been transformed during operation. Therefore, it is a value which depends on the
characteristics of the load.
HIMOINSA generator sets, equipped with an alternator, can deliver both the active
power and reactive power required by the load but, while active power is delivered
by the combustion engine (transforming mechanical power into electrical power
by means of the generator) reactive power is delivered by the alternator.
If the rated power factor is 0.8, the rated apparent power will be 1.25 times the
rated active power.
OPERATING CONDITIONS | PAGE 25
For operation with values other than 0.8, the following should be taken into
account:
LOAD WITH COS φ BETWEEN 0.8 AND 1
At rated active power the alternator works perfectly with cos φ values between
0.8 and 1. To avoid overloading the engine, it is essential not to exceed the rated
active power.
LOAD WITH COS φ < 0.8
The alternator, for the reference plate value of cos φ = 0.8, is overloaded more
as it approaches cos φ of 0. Therefore, the reactive power to be delivered
increases as the cos φ decreases. The generator reduces power according to the
indications supplied by the manufacturer. Under these conditions the combustion
engine generally presents high power.
By way of example, Table 2 is presented for the determination of these reductions
in power.
When the capacity of the charging outlet is an important requirement, the
Customer/User should clearly indicate this to HIMOINSA and must provide all the
information related to the various loads to be fed; their possible division into
gensets and the connection sequence. All this helps achieve the best
dimensioning of the genset and avoid both uneconomic oversizing and dangerous
undersizing.
4.5.6 SINGLE PHASE LOAD
The generator sets can become loaded with unbalanced loads reaching a
maximum of the nominal current in each phase.
This means that between two phases (e.g. between L1 and L2) no more than
0.58 of the three-phase rated power of the genset can be introduced given that:

Similarly, between one phase and neutral (e.g. between L3 and neutral) no more
Table 2
Coefficients indicative for reducing power of a generator according to cos φ than 0.33 of the plate three phase rated power can be introduced:

Power factor (cos φ) 1 0.8 0.7 0.6 0.5 0.3 0

Reduction coefficient 1.00 1.00 0.93 0.88 0.84 0.82 0.80

It should be remembered that during single phase operation or with unbalanced
loads, the voltage regulator cannot maintain the expected voltage tolerances.
NOTE
For greater precision, refer to the documentation provided by the manufacturer
of the genset. 4.5.7 START UP OF ASYNCHRONOUS ENGINES

Starting asynchronous motors by means of a generator set present problems, as

4.5.5 CHARGING OUTLETS
When a load is applied to a generator set, this often causes voltage and
frequency transients. The extent of such deviations depends on the power value,
both active (kW) and reactive (KVAR) of the load variations, depending on the
genset's characteristics (power and dynamic characteristics).
The genset's characteristics are result of the combination of the characteristics
of the combustion engine and alternator.
If further information is required, you may request the load impacts reports
produced according to standard ISO 8528-5 by contacting the HIMOINSA
Technical Department.
engines with squirrel cage rotors have starting currents eight times the rated
current (Istart-up=8 In), and a low power factor.
Under these conditions, the current absorbed by an asynchronous engine (or by
engines which start simultaneously) during starting, must not exceed the
maximum current that the generator can deliver in a short time, with a tolerable
voltage drop and not exceeding overtemperature limits.
To prevent excessive oversizing of the generator set, the following systems can
be employed for the cases raised:

OPERATING CONDITIONS | PAGE 26

VARIOUS ENGINES
Divide them among several gensets which are each introduced according to a
preset sequence, at intervals of 30-60 seconds.
A SINGLE ENGINE
Where permitted by the coupled operating machine, using a reduced voltage starter
system (star/delta or auto-transformer) or, for higher power engines with wound
rotor and rheostatic starter.
In the case of star/delta starting, the voltage in each phase is reduced and the
starting current (Istart-up) is reduced at the same rate, this being:

Therefore, in the case of an engine starting currents six times the nominal value
Istart-up = 6·In of direct starting, with star/delta starting Istart-up this will be reduced to
approximately 3.5 times the In, and consequently the power required to generator
will be reduced by 58%.

Istart-up

In all cases, both with direct starting and reduced voltage starting, it is necessary
to control the devices and users connected to the user circuit, trying to avoid
possible failures (e.g. contactors opening) caused by a transitory voltage drop
during starting.

OPERATING CONDITIONS | PAGE 27

5. USING THE GENERATOR SET

5.1 CHECKS PRIOR TO STARTING

These operations must be performed in the following situations:

•• Before commissioning
•• After installation of the genset
•• After a comprehensive revision
•• After maintenance operations
•• After a long period of inactivity

ATTENTION
During these operations, ensure that the genset cannot start unintentionally, that
it is locked and the starter batteries are disconnected.

5.1.1 EXHAUST SYSTEM

Check the correct installation of the tilting caps on the exhaust system, ensuring
they are correct attached and move properly.

5.1.2 RADIATOR WATER LEVEL

When there is insufficient water, it must be replaced with a mixture containing a

maximum of 50% glycol, as antifreeze solution or corrosion inhibitor, and the rest
clean water. Consult the engine documentation to find out the precise coolant
composition recommended.

5.1.3 LUBRICATING OIL LEVEL IN THE TANK

Checks must be carried out to ensure there is a sufficient oil level for proper
operation of the generator set, both in the engine crankcase, by viewing the oil
dipstick, and oil tank, if present.

USING THE GENERATOR SET | PAGE 28

The type of oil to be used is specified in the generator set's data sheet. For other 5.1.6 CYCLIC DIRECTION OF THE PHASES
types of oil, refer to the engine manual.
In gensets with parallel application, either automatic or standby manual
intervention for external production lines, check that the cyclic direction of the
5.1.4 FUEL SUPPLY
phases of the alternator corresponds to the cyclic direction of the phases of the
external producer, avoiding reverse engine rotation and other problems.
Check that the operating conditions of the combustion engine are met with
regards gaseous fuel, the absence of losses in the fuel installation and the
resistance and sealing testing. 5.1.7 CHECKING THE STATUS OF THE AIR FILTER
Check that the gas composition meets the requirements recommended by
The filters must be unobstructed and without porosities that prevent good air
HIMOINSA and by the manufacturer of the generator set engine. Then check the
filtration. If damage is present, appropriate maintenance operations must be
inlet and outlet pressure of the generator set gas train.
performed.
Check the sealing of the gas train: Check that there is no leak in the pipeline
section connecting the customer's gas connection, as well as all the equipment
5.1.8 CHECKING THE STATUS OF THE RADIATOR AND AFTERCOOLER
that composes the genset gas train. This check must be carried out using an
approved device. In the event of leakage, close all the manual valves, both the
Visually check that the air inlet surface of the radiators is free of dirt.
manual valve installed on the gas train, as well as the manual valves that may be
present in the customer's gas installation. Once all these valves are closed,
proceed to repair the leak, provided no gas is present in the section of the 5.1.9 CHECKING THE EARTHING
installation which is to be repaired.
Check that both the generator, as well as the installation that will be connected
Check that the fuel filters do not contain water or particles if the equipment has
to the genset, are earthed (connections, earthing rod…).
been used previously. Always do this with the gas valves closed.

NOTE 5.1.10 CHECKING THE EMERGENCY STOP BUTTON

If the generator incorporates synthetic flexible connecting hoses for the gas, it is
important to respect the recommended replacement times, as their durability Check that when operating the emergency stop button the generator set stops
will in no case exceed 10,000 hours or 2 years. The duration of metallic flexible instantly.
connections is 30,000 hours or 5 years.

5.1.5 ELECTRICAL RULES

Before starting up the genset, check the electrical connections, starter batteries
and earthing. The cable connections should be well tightened and free of
corrosion. Open all the switches.

USING THE GENERATOR SET | PAGE 29

5.2 COMMISSION Check that the inlet and outlet pressures of the gas train correspond to the
expected levels, otherwise proceed to adjust the relevant pressure regulators.
Check if the operating logic of the gas train functions properly:
ATTENTION
•• If the valve only opens when the starter motor is already spinning,
Installation operations must only be carried out by qualified, authorized and
and
competent personnel, with the owner of the generator set responsible for
ensuring these operations are conducted safely. •• If during the normal stopping process, the valve closes before giving
the stop command to the engine.
Recommendations:
1. Authorized, competent personnel responsible for the operation of the ATTENTION
generator set must perform the start up process. Remember that during the In the event that two unsuccessful starting attempts occur, it is recommended
start up process, the entire electrical installation of the generator set is to engage a start attempt with the manual valve closed to ensure no gas
energized. In addition, other equipment that are not part of the electrical builds up inside the engine, forcing the ventilation of the combustion chamber.
installation of the generator set may accidentally become energized.
2. Do not press the emergency stop button unless there is a risk to the generator
set and/or persons close to the generator set. This button should not be 5.3 CHECKS AFTER STARTING THE GENERATOR SET
operated for regular stops of the genset, thus allowing for the proper dissipation
of coolant heat and engine lubricant heat. The following checks must be performed:
3. Avoid low charge percentages. A minimum load of 30% of the rated power of •• Electrical checks (voltage, current, frequency, rotary field, etc.).
the generator set is recommended. This minimum charge percentage prevents •• Mechanical checks (oil pressure, water temperature, absence of
increased engine oil consumption, which leads to an increase in the durability of noise, etc.).
the generator set engine. •• Safety checks (emergency stop, oil pressure, water temperature,
etc.).
4. In the event the smell of gas is detected, immediately press the emergency
stop button of the generator set, next to the control panel, all available manual
valves must be closed and immediately leave the site of the generator set. This
will automatically close the gas supply to the generator set. Do not return to the
location of the generator set until after a few minutes, thereby promoting static
ventilation of the genset site.
5. Once it is possible to return to the site of the generator set, proceed to locate
the potential leak by opening the available manual valves one by one and
checking section by section, observing the assembly and gauges. Only reset the
automatic safety valve after confirming the location of the leak and having solved
the problem.
During the equipment startup process, check the operation of the safety solenoid
valve, the sealing checking system of this solenoid valve (if applicable) and the
reading of the pressure gauges when opening this valve. These reading are given
during the genset starting process and once the engine has stabilized at idling
speed.

USING THE GENERATOR SET | PAGE 30

5.4 ELECTRICAL PANEL BOARD 5.5 QUICK GUIDE FOR THE USE OF THE MAIN CONTROL UNITS

The generator set is usually equipped with an electronic protection and control
unit, with characteristics that depend on customer requirements, which may 5.5.1 CONTROL PANELS CEM7-G AND CEA7-G
include: protection devices (fuses, circuit breakers, differential switches, etc.),
measuring instruments (ammeters, voltmeters, frequency meters, etc.), control The visualization module has a backlit display and various LEDs for monitoring
instruments (fuel level, oil pressure, temperature, etc.), selection instruments (bi- the status of the control unit. It also has buttons that allow the user to control
frequency selector, fuel selector, etc.), voltage switches and output connection and program the control unit.
terminals.
Depending on the type of control unit, the operations and operating status of the
genset are shown with a set of lights or text. For information on these and other
indications and operations, refer to the documentation for the control unit that is
supplied with the generator set.

Fig.1
Front view of the display module

The visualization module has a backlit display and various LEDs for monitoring
the status of the control unit. It also has buttons that allow the user to control
and program the control unit.
1. Backlit display with 4 lines of 20 digits.

NOTE:
The display goes into low power mode (backlight off) after 10 minutes without
any button being pressed.
2. Control unit buttons
•• Control unit operating mode buttons
•• Control unit command buttons
•• Display buttons
3. Status LEDs
•• ENGINE status LEDs
•• ALARMS LEDs
•• CONTACTORS status LEDs

USING THE GENERATOR SET | PAGE 31

CONTROL UNIT BUTTONS 3. Display buttons
1. Buttons for control unit operating modes Confirm (V). Enters the menus and confirms the data
entered.
Lit LED: Automatic Cancel (X). Goes back through menus and cancels data
Automatic mode: The control unit mode active entered.
monitors the status of the genset and
manages its operation and the LED flashing: Up (+). Advances through the selection on display screens,
programmable inputs. Automatic mode the selection in maintenance menus and increases the
blocked programmed values.
Manual mode: The control unit is
commanded by the user. LED off: Manual Down (-). Goes back through the selection on display
mode active screens, the selection in maintenance menus and decreas-
es the programmed values.
2. Control unit command buttons
Genset contactor Enables/disables the genset contactor
Engine start button (only in manual mode). Manages start-up (manual mode only).
with one touch.
Lit LED: Engine starting
STATUS LEDS
Engine stop button (only in manual mode)
1. ENGINE status LEDs
The first press to stop engine while performing a cooling
cycle. The second press to stop the engine immediately.
Lit: Engine started detection
Lit LED: Engine stopping (with or without cooling). Engine started
Off: Engine stopped

Alarms reset button. Allows the user to eliminate acoustic

signals and to report the alarms. Lit: Enables the gas ramp
Gas ramp
LED flashing: Alarms pending notification Off: Engine preheating disabled.
Lit LED: Active alarms
Lit: Engine start activated
Engine start-up
Off: Engine start deactivated

Without use, does not apply Lit: With engine running, voltage in the
Alternator status, battery charging alternator is detected
battery charging Off: Engine stopped or started, with no
voltage in the battery charging alternator.

USING THE GENERATOR SET | PAGE 32

2. ALARMS LEDs 5.5.1.1 OPERATING MODES

Gas pressure MANUAL MODE

In manual mode, the control unit is commanded by the user via the front panel of
Battery level the visualization module. The user can start and stop the engine by pressing the
START and STOP keys respectively.
High temperature

Engine start-up failure Lit: Analogue sensor alarm

Flashing: Digital sensor alarm
Overspeed Off: Without alarm
Pressing the START key initiates the engine starting procedure (without
deactivating the network contactor CEM7 + CEA7CC2). Pressing the STOP key
Low oil pressure
initiates the engine stop operation with cooling; a second press of the STOP key
Auxiliary 1 (freely programmable) causes the engine to stop immediately without waiting for the cooling time.

Auxiliary 2 (freely programmable)

NOTE
For more details on alarms, please refer to the professional instruction manual
of the digital control unit x 1 click x 2 (double click)
WITH cooling WITHOUT cooling
Activation of the genset contactor on the CEM7PG visualization module is
3. CONTACTORS status LEDs (CEM7G + CEC7) performed by pressing the GENSET key.
These LEDs only appear active when the transfer switch controller is connected.
Start-up option due to Voltage Grid Failure (CEM7G + CEC7).
The reference symbols M and G which appear on the front of the control unit are GENSET

only activated when the transfer switch controller is connected.

In order to achieve activation of the genset contactor, the engine has to be

Network contactor status
Genset contactor status
Lit: Contactor active running and provide a stabilised electrical signal.
Flashing: Contactor in the
connection/disconnection
phase
Off: Contactor disconnected

USING THE GENERATOR SET | PAGE 33

AUTOMATIC MODE
In automatic mode, supervision of the installation is managed by the control unit.
Under certain circumstances which can be programmed, the control unit starts
the genset to supply the installation.
MODE LOCKING FUNCTION
Pressing the Auto or Man keys for 5 seconds activates the locking of the mode.
This status of the control unit is indicated by the flashing of the button for the
mode currently active. To deactivate the mode lock and allow normal operation of
the control unit, press the key associated to the active mode for 5 seconds.
PRACTICAL EXAMPLE OF A START-UP OPERATION
NOTE
Before starting the start-up cycle it is advisable to ensure the genset's main
circuit breaker is in the off position (OFF).
By pressing the START button the start cycle is initiated and is indicated by the
START button's LED switching on. At the same time, the gas train verification
process is initiated by the PR output switching on for a programmed maximum
amount of time until it detects the gas pressure verification input. Once the gas
train activation process begins, the corresponding LED of the control unit ( )
remains lit until the engine stopping process begins.

5’’ Locked 5’’ Unlocked Fig.1

Once the presence of gas at the engine input has been verified, the engine start-
up output is enabled and, a little later, the PC output. The engine start-up process
is indicated by a LED in the control unit ( ). A little later, the output dedicated
to the activation of the gas solenoid valve is enabled, so that gas may enter the
engine. The ARR output remains enabled for a maximum amount of time until it
detects that the engine has started running, otherwise it re-initiates the engine
start-up process.

Fig.2

USING THE GENERATOR SET | PAGE 34

Once it has been detected that the engine is running the LED switches on ( ), To interrupt the start cycle, just press the STOP button
this indicates the end of the start cycle and the START button turns off.

Fig.5
Fig.3

The LED corresponding to the battery charging alternator voltage ( ) switches NOTE
on when the voltage provided by the alternator exceeds the voltage threshold set The display shows the engine status screen, where the engine status is displayed
by default. during the start-up operation. This sequence is:
Genset: Stopped
Genset: Starting
Genset: Started
Genset: Stable
Genset: Loaded

NOTE
Start-up in an automatic system, or using an external signal, etc. is carried out
following the same process as when starting up manually.

Fig.4

If during the start-up cycle, the engine started condition is not detected after 5
seconds, the ARR output deactivates and the corresponding LED turns off
( ).
Subsequently the control unit automatically attempts a new start-up, repeating a
new cycle without the need to press START (4 cycles by default). After exhausting
the attempts to start the engine without success, the control unit display shows
the alarm (START FAILURE).

USING THE GENERATOR SET | PAGE 35

PRACTICAL EXAMPLE OF A STOP OPERATION After concluding the cooling time (120 seconds by default), the PC output is
disabled or enabled according to the type of engine to carry out the stop, the
NOTE STOP button and the LED ( ) for the started engine switch off (2).
Before beginning the stopping cycle, it is advisable to ensure the genset circuit
breaker is in the off position (OFF).
The genset can be stopped in various ways:
Manual with cooling: pressing the STOP button once. To perform a stop with a
cooling cycle. The safe stopping cycle will close the gas valve while the engine is
still running to ensure the combustion of the waste gas in the internal supply
pipeline and in the engine itself.
Emergency manual: pressing the STOP button twice. To perform an emergency
stop without a cooling cycle. In this case the safety stop is not carried out so
that gas can remain inside the supply system and even the engine itself. This
can produce some temperature detonation in the exhaust line. To avoid this, it is
Fig.2
recommended to stop the engine by stopping with cooling.
If after a period of time any engine running condition is detected, the control unit
Automatic: After deactivation of the command enabling the automatic start-up
shows on the display the STOP FAILURE alarm and the LED of the STOP button
and therefore performing a stop with cooling.
remains lit (3).
Sequence: We press the STOP button once and begin the stopping cycle with
engine cooling. This is indicated with the STOP button lighting up. (1)

Fig.3

Fig.1

USING THE GENERATOR SET | PAGE 36

 5.5.2 DEEPSEA CONTROL UNIT
The LED corresponding to the battery charging alternator voltage ( ) switches
off when the voltage provided by the alternator falls below the programmed FRONT OF THE VISUALIZATION MODULE
voltage threshold (4).

2 3

10 4

Fig.4

NOTE
An engine status screen is shown on the display, indicating the status of the
engine during the stop operation. This sequence is:
9 8 7 6 5
Genset: Stable
Genset: Cool down CONTROL UNIT BUTTONS
Genset: Stopping 1. Navigation buttons 6. Cancel Audible Alarm button
Genset: Stopped 2. General Display 7. Automatic mode button
3. Programmable LEDs 8. Manual mode button
4. Switch open button 9. “Stop” button
5. “Start” button 10. Switch close button
ENGINE START-UP
4. First Select Manual Mode
5. Press to Start-up the Engine
STOPPING THE ENGINE
Press to Stop the Engine

NOTE
For more information refer to the corresponding manual.

USING THE GENERATOR SET | PAGE 37

6. LPG RENTAL UNITS 6.1 CHARACTERISTICS OF RENTAL LPG (PROPANE) UNITS

These units are characterized by having integrated LPG (propane) tanks. This 6.1.1 OPERATING DIAGRAM
chapter describes those additional functionalities to standard gas units. Both the
safety measures and operating instructions described earlier in this manual
must also be observed for units with integrated tanks.

1.  LPG Tanks 5. Three-way catalyst

2.  Vaporizer 6. Residential silencer
3.  Optional gas train 7. Gas presence sensor
4.  Engine gas inlet 8. A, B and C Fuel sources

USING THE GENERATOR SET | PAGE 38

The installed storage capacity (1) may vary from model to model. The useful ca-
pacity is 80% of the installed volume. The system itself limits filling to this capac-
ity to leave room for the expansion of gas in a liquid state. Tank overpressure
valves lead to outside of the tank area. The compressed and liquid phase gas (A)
from the tanks circulates through the vaporizer (2) which gasifies it and regulates
the pressure to adapt it to that required by the engine (4). The engine's cooling
water circulates through this vaporizer to prevent it from freezing due to the pres-
sure jump. When opting for external supply (C or B), this will be in the gas phase
(according to options) and will circulate through the gas train for its regulation
(3). After this, the gas will be directed to the engine intake (4).
6.1.2 FUEL STORAGE
A Rental generator set, in addition to the parts described for the open-skid or
soundproofed static generator set, incorporates a separate chassis housing LPG
storage tanks:
1.  Fuel intake
2.  Relief valves
3.  LPG tanks (3 units)
4.  Gas presence sensors
5. Insulated chassis
6. Lifting point
7. Side openings for tank maintenance
8. Ventilation grids
6.1.3 FUEL SELECTOR
HIMOINSA generator sets with an integrated tank can be powered by one, two or
three gas fuel sources, according to the version. By default, the option of feeding
through the interior tanks is included. In addition, if the external fuel supply
option is included, a two or three-position selector will be incorporated in the
control panel (depending on the version), to be able to select from among the
different fuel sources, these being:
Position A: Liquid-phase propane from internal tanks
Position B: Propane in gas phase from an external source (optional)
Position C: Natural gas in gas phase from an external source (optional)
ATTENTION
You should always consult the HIMOINSA Technical Department regarding
accepted gas compositions. The compositions are very varied, even within the
same country, and can adversely affect operation of the equipment, even
causing failures or accidents.
6.1.4 FUEL REGULATION SYSTEMS
In order to identify the gas train equipment, two different images are highlighted:
6.1.4.1 Liquid-phase gas train (Propane)
The gas in liquid form exits the tanks towards the vaporizer, where it passes into
a gaseous phase and its pressure is reduced to a suitable level before entering
the engine. To prevent the vaporizer from freezing due to the pressure jump, the
hot engine cooling water passes through it to keep it at operating temperature.
USING THE GENERATOR SET | PAGE 39
 6.1.4.2 Gas train in gaseous phase (Propane or Natural Gas)

In units with the external fuel supply option, fuel will always be in gas phase, so
the standard gas train of the gas range will be incorporated.
1 5 2
3
4

1.  Manual ball valve

1.  Manual shut-off valve
2.  Inlet pressure gauge
2.  Inlet pressure gauge
3.  Outlet pressure gauge
3.  Gas filter
4.  Gas filter
4. Solenoid valve
5. Primary pressure regulator (*)
5. Vaporizer
6. Double solenoid valve
6. Engine cooling water connections
7. Low pressure gauge (**)
7. Liquid phase inlet connection
8. Gas phase outlet connection * Secondary pressure regulator installed in the engine, upstream of the mixer
** Optional: High pressure gauge

USING THE GENERATOR SET | PAGE 40

6.2 VALVE BOX 6.3 MAINTENANCE

When you receive your LPG rental unit, the manual valves that allow the flow of For maintenance access to tank valves, remove the side cover of the chassis.
gas from each tank will be closed as a safety measure. Remove the front cover Unscrewing the watertight cover in the picture gives access to the tank control
of the chassis to access them and open the three valves labelled with tanks 1, 2 system.
and 3 (depending on the version). In the event of a tank malfunction, you can
isolate it by means of its corresponding valve so you can continue working with
ATTENTION
the unit while requesting immediate repair.
This operation should only be carried out by properly trained personnel who are
experts in handling automotive LPG tanks.
DANGER
Never handle the valve that is sealed and labelled DANGER. This valve is for
internal use only and must not be tampered with under any circumstances.
In the front box you will also find the tank area gas leakage sensor and watertight
electrical connection box.

2
4
1 3

In addition to the maintenance already described in other chapters, especially

with regard to the inspection and/or replacement of gas and fluid pipelines,
tanks and their subsystems are also subject to regular maintenance.

1.  Tank shut-off valves 3.  Gas sensor The generators have side openings for easy access to the tank valves. These
2.  Valve for internal use (DO NOT TOUCH) 4.  Electrical connection box valves have visual level indicators that can help identify a failure.

USING THE GENERATOR SET | PAGE 41

6.4 REFUELLING 6.5 SAFETY

Refuelling the generator will depend on the availability of different sources of liq- Rental units with integrated tanks have two gas leakage sensors: in the engine
uid-phase LPG (propane). It has a fill inlet on the side of the chassis protected by area and in the discharge area of the tank overpressure relief valves. These sen-
a key. Inside you can find a standardized thread and an adapter for autogas. This sors are only active if the main power switch on the control panel is in the ON
adapter can be purchased in each country to adapt to the most common inlets position. Only in this case will the sonic and visual alarm be available. It is possi-
(bayonet, ACME, Euro, etc.). Refuelling should always be done with the generator ble to separate the power supply to the sensors from the generator set activation
stopped. switch on request. In this case, if the generator set is not in operation, it will be
necessary to power the batteries via the external charger to prevent them from
1. Autogas - In cases where the unit is on a trailer, and if local regulations allow,
being discharged.
it is possible to refuel the unit in autogas stations. Please check that its compo-
sition is admitted by the engine. Observe all the safety measures required for
this operation.
2. LPG tank and autogas skid - It is possible to refuel the unit by means of an
LPG tank and its corresponding autogas skid.
3. LPG lorry - In certain countries there are LPG distribution networks in small
lorries that can refuel the generator on site.

DANGER
Observe the safety regulations at all times when refuelling. Do not smoke or use
your mobile phone. Check local regulations that apply in your case.

DANGER
In the event that the generator set switch is disconnected, the gas leakage
sensors will not act, meaning you will not be warned if there is leakage.

USING THE GENERATOR SET | PAGE 42

7. MAINTENANCE

ATTENTION
Maintenance of gas-powered units should only be carried out by qualified and
properly-trained personnel. Any tampering with gas systems can lead to the risk
of personal injury and property damage, including death.
A suitable maintenance and revision programme, performed only by qualified
technicians, is essential to maximize the reliability of the engine, minimizing
repairs and reducing long-term costs.
To carry out an effective maintenance programme, it is recommended that any
data obtained during operation be collected, using the timer operation of the
generator set to keep accurate records of all the services performed. This record
will also be important for warranty issues.
For specific maintenance plans related to the Generator set acquired, refer to the
appropriate documentation for the engines, alternators and certain accessories.
These plans vary according to:
•• Hours of operation
•• Fuel quality
•• Machine location
•• Type of load supplied
•• Environmental conditions
Therefore, once the genset has been received and taking into account the above
elements, these maintenance plans should be studied to determine the
maintenance intervals which need to be carried out.
In addition to what is mentioned in the specific maintenance plans for each
engine, there are a number of operations that must be carried out on a mandatory
and regular basis to ensure safe operation of the unit, regardless of the hours of
operation. These are:
Inspection after the first 50 hours of operation. Check all joints where gas,
cooling water, oil and air/gas mixtures circulate in order to detect possible
leakage. Check the tightness of all these joints.
Monthly. Visual inspection of all pipelines, joints and devices in contact with gas
fuel. Replace in case of damage, deterioration or improper functioning.

MAINTENANCE | PAGE 43
Annually. Inspection of the unit by an authorized gas installer, who will use an
approved leakage detector to check that there is no fuel leakage. Replace those
elements with an expiry date, such as flexible pipeline hoses.
Every 5 years all hoses in the unit must be replaced, whether they are gas,
cooling water, oil or air/gas mixture circuits. Metal gas hoses have an unlimited
lifespan unless they are damaged by blows, scratches, cuts, etc., in which case
they must be replaced immediately.
If the unit incorporates gas storage tanks, these must be checked and resealed
every 10 years.
It is important to perform continuous cleaning of the generator set, also avoiding
the accumulation of fluids on both the internal and external surfaces as well as
the acoustic materials installed. To perform the cleaning do not use flammable
solvents, it is recommended that aqueous liquids for industrial cleaning are
used.
It is recommended that the genset be started at least once a month if it is not
used over long periods, allowing its status to be checked.
Depending on the application and environmental conditions, maintenance
periods may be severely reduced. Please note that these maintenance intervals
are only recommendations. If you have any doubts, please contact the HIMOINSA
post-sales department.

MAINTENANCE | PAGE 44
8. WARRANTY
The warranty period shall be as specified in the Warranty Certificate issued by
HIMOINSA. For contractual cases, this warranty period will be different: it should
be established in advance in agreement with HIMOINSA Management. HIMOINSA
generator sets generally have a warranty with a duration of 1 year or 4,000 hours
or 18 months after departure from the factory for applications in continuous
power and 2 years or 1000 hours (500 hours/year) or 30 months after departure
from the factory, for standby applications. In any of these applications the
warranty period starts from the date of commissioning, or otherwise 3 months
after the invoice date (if the genset is to be stored for longer than 6 months, this
must be reported to the after-sales department).

8.1 OBLIGATIONS

The end user must fill out the warranty certificate submitted with the purchase
receipt with the date of commissioning of the machine, within the stipulated time
limit and providing all the required data.
Warranty requests cannot be considered as such, unless the commissioning
registration form has been previously received by HIMOINSA, within 10 days after
commissioning, or 30 days after sale to the end customer.
The customer must provide, prior to the commissioning of the equipment, a
complete analysis or chromatography of the fuel gas. HIMOINSA shall indicate
whether this gas is APT or NOT APT for use in the equipment supplied and the
de-rating needed to operate the equipment safely. This requirement is obligatory
to validate the warranty. Otherwise HIMOINSA will not take responsibility for it.

8.2 WARRANTY FOR SPARE PARTS

The spare parts replaced in a genset still under warranty, assume the remaining
portion of the genset's standard warranty.

WARRANTY | PAGE 45
8.3 STORAGE OF GENSETS DURING THE WARRANTY PERIOD
When long-term storage of the generator set is necessary, HIMOINSA is not liable
for damage caused by negligence or failure to comply with the storage procedures
described below:
All machines must be stored in a controlled environment, indoors and not subject
to extreme variations in temperature and humidity.
In order to prevent oxidation of the internal parts of the engine, engines must be
prepared for long periods of inactivity, with a long period of inactivity in storage
considered to be greater than 6 months. The following recommendations are
general, it is essential to consult the specific Use and Maintenance Manual for
each brand of engine:
•• Discharge the engine crankcase oil and completely empty it, put
protection oil in the engine crankcase (e.g. Cepsa Breaking-In and
Protection SAE 30).
•• Rotate the engine for at least 10 minutes, spray engine protection oil
(SAE 30) through the inlet for 1 minute.
•• Drain the oil from the crankcase and seal the intake, exhaust,
ventilation and respiration devices, if present.
•• Drain the cooling system.
•• Place a specific sign indicating that the equipment has no oil and
antifreeze.
•• Loosen the V-belts.
•• Disconnect the batteries and store them in a dry place keeping them
always charged.
NOTE
This procedure is important, repeat every 6 months.
For commissioning of the generator set after a long period of inactivity and
reactivating the warranty, the following actions should be performed:
•• Drain the protection oil.
•• Replace the oil and fuel cartridges, if the one-year conservation
period has elapsed.
•• Fill the oil crankcase to the maximum level with specific oil.
•• Fill the fuel system.
•• Check all the sealed systems.
•• Tighten and check all the belts especially on the straight section
before bending around the pulley. Check that there is no rust on the V
of the pulley.
•• Connect the fully charged batteries.
•• To test the machine checking all readings and the operation of the
different measurement and protection systems.
•• Check for oil, fuel or coolant leaks.
8.4 EXCLUSIONS
HIMOINSA shall not be responsible for additional costs such as:
•• The use of unauthorized oils and fuels.
•• Prolonged or improper storage as well as any other form of misuse or
poor maintenance.
•• Alterations or repairs which have not been authorized by HIMOINSA.
•• Damages and costs of prolonged operation of malfunctioning
equipment that could have reasonably been detected.
•• Rental costs or transportation of replacement equipment during
repair, or expenses and/or the task of connecting the equipment to
other equipment owned by the customer.
•• The choice of a genset which is unsuitable for the application, and/or
lack of compliance with the installation instructions and rules for use
and maintenance, may invalidate the warranty.
WARRANTY | PAGE 46
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www.himoinsa.com
HIMOINSA reserves the right to change any feature without prior notice.
The illustrations may include optional equipment and/or accessories.
Not contractual images. The technical indications described in this
manual correspond to the information available at the moment of
printing.
HIMOINSA ® - 2020 © All rights reserved.