ENERGYSELECTAIC DIESEL GENERATOR OPERATION & MAINTENANCE MANUAL OF DIESEL GENERATOR www.DATEG.or.krCO Ng@aaeey T S 1. Safetynstruetions .1 Merit of Operation Diary Recording Fanation of Equipment 2.1 Explanation. tallation of Equipment Installation Ventilation andWischarge Facility — Earth 33 34 Vibration 3.5—§(Connection to the load 4. Operation of Equipment 41 Outline 4.2 Function of Running Panel 4.3 Operation of Equipment 4,4 Running under Any Specific Conditions — 5. Preventive Maintenance and Breakdown Excluding 5.1 Preventive Maintenance 5.2 Breakdown and Its Countermeasure 6. Maintenance of Generator 6.1 Maintenance of Generator 6.2 Maintenance of Switch Box and Running Panel 6.3 Maintenance of Base 6.4 Safety Operation 6.5 Howto Use Storage Battery 15, 16 7 2 ge 33 35 35. 36 a7 www. DATEC.or.kr1. case you contact the voltage occurring from this gencrator se, as you will be in danger andl even i¢ would be fatal, so you must be careful or considerable in operating or maintaining the generacor Before Operation ~ Before using it, take a look at and read his manual to understand the contents about the generator and to use it properly = In case the generator is installed in the dosed place, place ventilation system at any cost. = Pur the set to earth by all means In Operation = Ifany questionable matter is found in operating the set, stop it in no time and analyze the cause to take any proper action. = Don't replenish any fuel in operating the set. After operation — Put the circuit breaker to the position of “Off” — Don't couch emission pare (muller) In case you do it, you may get burned. @ Marks such as PEIN PEIN PEE ©, @ are used to alarm the seriousness and warning of danger for the conditions such as below cases PERCENT Danger: Ifyou dont follow the regulations, you might die or get hurt. PREZENIN Worning Ifyou don't follow the regulations, any accident may happen, or the generator may be out of order or broken. PWSTEIE Cousins This isa condition to maintain the operation and state the optimal state. ® Abnormal (Wrong) © Normal (Proper) www.DATEC.or kr1.1 Merit of Wi ® “Operation Diary” informs accurately the user or manager of the state of generator. Also, it is prevention & maintenance plan and. ives the below effects. = Error searching effect: Tehelps you to comprehend the exact position of defect. — Ichelps to reduce a period of maintenance. = Ichelps you to comprehend an exact state of operation, A. Recordable Items ® Next items are for daily record. = Operation period = Engine oil, Amount of fuel ~ Pressure of engine oil — Exchange period of engine oil = Maintenance result of maintained components and kinds of ‘maintenance (Adjustment, repairing, exchange) = Change of the state during operation (e.g, black smoke is emitted.) EXIT Comprehend the manual to be familiar with operating and stopping the generator. S PREEEE Wear safety helmet and safety shoes by all means. If any difficule matter is seemed to happen, wear safety gloves, protective goggles, carplugs and antigas mask. @ Before Operation oil system oF the refueling state of engine happens. more time within the coverage of its operation. wom ting Operation Diary #2222202 2800008 LE a a EXCIISI Before starting the generator, check if any leakage for fuel and FXENEM In starting the generator, observe the obstacles and people one z www.DATEGonkr 4— . @ In Operation FREI Don't touch any movable part of the generator. (Clothes or hair might be stuck on the movable part and you ‘ight be in danger to hurt or dic. Dont touch any hot components such as emission [i cancer | Peso pipes while operating the generator or on the morrow of stopping the engine. XESS If you should operate the engine at the closed place, ventilate icand install ventilation facilities at any cost. @ After Operation (CNSLI After finishing the operation, inspect or fix the ig the op Ps connected part for next operation.. @ Maintenance ERENT Before maintaining the engine, check if any dangerous factor such as the engine stopped thoroughly and then maintain the engine. [XENI Use the tools proper to the components. (Dont use any tool that may impact the engine or hurt the operator.) ® www.DATEC.or.krEXEEEE Avoid ignicing substance while dealing with inflammables. FREESE Dont go up to the engine to repair its upper side and use safery scaffold. XEN In moving the generator, apply the crane, forklift truck and other safe tug equipment. o 82. 41. 534. 4561 {f any problem occurs, contact us right away, Dafec Maintenance Service Co. Ltd. heles you with good faith. www.DATEGonkr 62. Explanation = . 2.1 Instruction Function ® This generator set is an AC reserve power equipment driven by a diesel engine. Ieis an apparatus changing mechanical energy into electronic energy designed to supply electricity by generating current within the conducting wire through magnetic field caused by movement of the rotator directly connected to the engine and relative movement of the conducting wire. ‘The alternating current generated by the magnetic field produced by rotation of the engine at the armature of the exciter in the rotator connected to the crankshaft and relative movement of the conducting wire is ‘converted into direct current passing through a silicon rectifier. The direct current is then supplied to the ficld magnet of the main generator to produce magnetic field and the output of the main generator is produced by relative movement. ® The engine is started by starting electricity and the type of fuel injection is direct injection type. There is no ignition device and autoignition is achieved by injecting fuel chrough actions of injection pump and injec tion nozzle when the temperature reaches 550 °C by compressing the fuel mixer with a high pressure. Structure © The generator is composed of a main generator and an excite, and each generator is consisted ofa stator and a rotator. D The stator is located inside the stator housing and the rotator is connected to the flywheel of engine crank- shaft through the rotator shaft. ‘The rotator contains a fan for self-cooling and bearings for rotation. www DATEC.on.kr3.1 Installation Outline > In case of installing the generator set, examine whether is for temporary installation, permanent installation oF outdoor installation before installing it. Installation at the Outdoors > Install the generator set on the place where little mud, sand and dust exists. ‘The place for insallaion should have any obstacle, excellent ventilation state and even surface. In case of installing it t che place where ground isnt so stable, concrete the ground with usable materials such as wooden planks and timbers before its installation. Considering the direction of wind and exhaust pipe, select any place where exhausted gas doesn't damage. Select the place that the generator set can be protected from cold wave raging during the season of intense cold. Installation at the Indoor Space {® Power generator chamber always should be ventilated. Install a discharging facility emicting the exhaust gas at the outside in its installing. ® For the base of generator chamber, select the place which can bear enough any vibration due to the weight or oper- ation of the generator to install the set. ® Secure any space enough to refuel, maintain and operate the set. Generator chamber should be installed at the place where fuel supply is easy. www.DATEGorkr 83. Installation ‘The size of generator chamber ® ‘The ratio of width and length of the generator chamber may as well become 1:1,5~1:1.2. The height of the ceiling should be determined according to the height where pistons reach, chain block is mounted and the distance beeween the block device and ceiling is considered. As a general rule, the distance mostly should be 4-5ms. Foundation of Installable Place } Foundation for installation should have the enough strength bearing the vibration occurring due to sel weight and operation. Make sure that vibration occurring during its operation doesn't reach at the facilities and buildings. Also, increase the weight of the foundation to reduce the transmitted vibration, Major Functions of Foundation (Base) ~ Ir supports full weight of the power generator (facility). ~ Ie keeps the assembled state of the generator and other equipment. = Ir keeps the generator (facility) from outer vibration. Design of Foundation (Base) ~ Calculate full weight of the generator (Faciicy). ~ Full weight includes the weight of all kinds of liquid such as cooling water, fuel and lubricant, and the generator mounting auxiliary equipments. The weight of fluid Coolant 1g/cm?, Lubricant 0.916 g/cm? Fuel oil(Diesel) 0.855 g/cm? 9 Sr M eon www.DATEC.on. ke3. Installatio: Foundation of Concrete ® To decrease the amount of transmitted vibration, increasing the weight of the foundation, examine if su- portable inner force stand enough against che weight and basic weight of the generator (equipment). ‘In case the foundation isnt enough to bear the loads, increase the basic area or drive in piles. ~ The length and widch of the foundation (base) should be 30cms larger than those of generator. = You should determine the depth of the foundation (base) according to the below context. 2,402.8xB xL ‘W = Full weight of generator (kg) / 2,402.8 = Dens of concrete (ky3) |B = Wid of foundation (base) (mn) /L= Length of foundation (base) (=) ® ‘The composition of concrete shall be as next context; sand: gravel (maximum size = 10¢a) :3. Then, cure it for 4 weeks to make its compressive strength 2,700kg/om, ® The iron bars of No.8 gauge (about ©4mm) should be used for the base. Reinforce the foundation, com- posing all the iron bars at interval of 15cms in length, width and height and inserting them until they reach at the depth of more than 7.5cms from the surface of the foundation, ® In case the generator shall be operated in parallel, design the foundation to be installed more firmly chan that for operation by itself to prevent its pull-out and to bear against the rebound of rotator power, The foundation should stand against double whole the weight. Spa F raw www DATEC.or-kr 10. Installation Natural foundation @ Solid soil, gravel or sand can take the role of an excellent natural foundation but this form of foundation can be used only when it can endure the pressure of the generator (facility). It is widely used as a temporary foundation. MaterialSatety Load Safety Load Material Kos rae? | Pal Rock, Har ground ayer we 30 Ey ‘Sold so, rave, course gitsand 8 0 = ‘rumbiy medium and ol 1 20 2 ‘rumbiy fine sand wee 10 v6 ‘Sorte! woe | ono | in © The pressure caused by the generator (facility) is the rotal weight (W) divided by the area of contact surface (A).. P(kg/cm’) = ae, @ The vibration of the engine depends on the location and method of installation, and vibration caused externally ‘when transferred to the engine may damage the engine, especialy if it was not operated for a long period of time. Foundation in the case of generator equipped with a vibration-proof device @ In case the facility is installed indoor, in general, a vibration-proof device is constructed by inserting rubber pieces or springs underneath the common base to lesson the vibration transferred to the foundation. In such a case, the. depth of the concrete foundation can be decided so as to endure the appropriate pressure without considering the increase of load to be caused by vibration, Also, as there occurs abnormal vibration when the generator passes the point of resonance during starting and stopping process for I xo 2 seconds, external facilites (example : exhaustion pipe, ete) have to be connected to the generator using flexible couplings, which will prevent failure of the system caused by vibration. Installation of the equipment + Installation of the equipment shall be started after completion of the construction of foundation for installation for the generator set. = In case ofa place where foundation construction is completed, the equipment shall be moved in and installed after placing it on the base bolts. = In case the equipment is temporarily installed where chere is no foundation, it shall be installed afte leveling the ground. NOTE Icwill be efficient if an adequate buffering device is installed beeween the equipment and the base bolts. — 41 Pr F oe www.DATEG.or.kr3.2 Ventilation and Discharge Facility Ventilation Facility O In case of installing the chamber at che indoor space, ventilate it, opening the windows or installing ventilating fan. > When installing the generator set ata closed space, installa discharging facility to eliminate the exhaust gas out of the space. In case thar the exhaust device penetrates the wal chat the danger of fire might occur, don't let the exhaust gas leaked from the connected part with a muffler. Countermeasure against Noise (D The source of noise transmitted from the generator (facility) is classified into the mechanical noise from engine, noise of intake & exhaust, noise of vibration and noise from generator set. Among these, as noise of vibration and from generator is gentle, most of noise from the generator occurs at the engine. (® Noise preventive aw againse mechanical noise isa very tough issue. Presently, a method not ro transmit noise is adopted, ! Cautions As the exhaust gas contains mono dioxide and does harm to our bodies, we can reduce it by any level but it’s difficult to decrease it perfectly. — : Spa M eon www DATEC.on.kr 123.3 Earth ® Put the generator set supposed to be completed to earth. @ In case the equipment is out of order, earth of the generator set makes the current co the iron safe or protects the generator set from a stroke of lightening. @ For the earth construction of the generator set; refer Table 1. SY Order | Classification Material, How co Earth [Bronze Pole 152 | Fiuhe eth wire to the cath teal and pole ough 1 Earth Pole | Mild Steel Wire weld a bole and then bury unl it reaches 2m in for Earh Wire 1,60 | $ept of underground, Bronze Pipe 199 | Facthe cath wie oth earth cial and pipe through 2 Piping Mild Ste Wie | weld or ols and dhe buy nul aces 2 in forRarth Wie 1.62 | depth of underground Brom Pate 0.:0.Sm | Fc dhe ca wc to theca exminal and pla ough Oe veld orbols and then bury it unt it aches 2 in il Set Wine er etn for Ear Wie 60 | “Pho endenround 3 | Earth Plate ! Cautions Dorit star or operate the generator set without earth Electrical accident due tothe generator, load wire and load itself may result in electrocution due to the comtact with the uncarthed field. Table 1. el Kind of Earth Construction Application Condition of Earth IseKind of Each Consracion | Sdhghlageastani stone tes Below 10/ 150 re rim Banchad arene A) cfarh Coourucion | Fit lth cetera emia of etsoner | (caval pocgean i bef 2nd Kind of Earth Con conning iprcirentandlow-ument| | ganfere esate me 0 | smo deaced) Sew 100/ rd Kind of Earth Comsruction | Ses devcelinemamens of newts (in cae of potting arth fuel be low SOD, nda oft be (nee ofpe Baow 107 Bre devfinarumen of og ot ‘is Kind of Spal Ean Coneton | Ems dirname (Iacncofproaig cach Eel be SOV ad xo ote box soir 13 Sn Feon www. DATEG.or. kr3.4 Vibration Prevention of Vibration © The generator set is designed to bear the vibration of it. In spite ofthat, if you prevent che generator from vibrating, the effective life of generator will be elongated and any efficiency will bring into an action to prevent any breakdown, due to outer vibration, Hence, install vibration-proof device against out vibration to protect the bearings and axis from any error. Vibration-proof Device «@ The most effective vibration-proof device is made of steel spring. This shows the vibration effec of about 96%. Ifyou installa rubber tube bencath the spring, you can block high frequency transmitted through the spring. @ As long as vibration-proof device made of rubber also doesn't show so serious vibration, you can use it, Reasonably ‘manufactured rubber vibration-proof has the vibration-proof effect of 90%. 3.5 Connection to the load Connecting Cable between Loads ® To connect the load cable, loosen the nuts on the output terminal, insert cables and cable, and fasten the nuts, tightly. ! Cautions Ifyou fasten the nuts of output terminal, any loss of current may occur, Fasten them tightly. www. DATEC.or.-kr 14,— 7 4.1 Outline Condition of Operation @ Peripheral ‘Temperature: -10°C ~ 40°C. @ Relative Humidity: Below 85% Condition of Installation @ Any influence shouldn't occur due to dust, sand, vibration and pollutane. @ Make ventilation device worked on an even keel to reduce the amount of heat emitted from the engine and other body. @ Altitude: Below 1,000m @ Installable Place: Outdoors and indoors ‘Trial Run ® Operate the diesel generator for 10 minutes pwice a month for trial run. ® Operate related generator for 15 minutes under the maximum load of 30% every each 31d tial run. @ Sometimes, besides regular trial run, operate related generator under the load of more than 30% 15 Pn Fra04 www.DATEGorkr4.2 Controller Engine controller ® Hand Type ~ Devices, instruments and alarm lamp mounted on this typed engine generator can start and stop the engine, regulate the speed, monitor the operation, look straight decremented pressure of lubricant, over-speed and engine, and alarm. ® Auto Type ~ All ehe functions are the same as hand type, and a junetion box connecting a body separable type and each operable line. Operable Panel of Generator ® Hand ‘Type (Mounting ‘Type and Body Separable Type) = You can monitor clecricigy sources and quantity of the generator. ~ You can Input certain load and cut off the current with hand. Semi-auto Type (Mounting Type and Body Separable Type) = You can monitor electricity sources and quantity of the generator. = You can start or stop the engine under the circumstance of power failure or power recovery of current sources in commercial use, ~ You can start or stop the engine with hand. ~ You can Inpuc certain load and cut off the current manually or automaticaly. @ Auto Type (Body Separable Type) ~ You can detect power failure or decrement of voltage in commercial use. = You can start the engine afier confirming if power failure occurs, distinguishing it from the power failure while lecttic power is given out of = You can start the engine triple in a row as a countermeasure against Ist failure. ~ If the number of rating rotations and constant voltage greets, a circuit breaker is operated automatically. ~ Check the recovery of current in commercial use. ~ Ie transfers any applied load from the current sources of generator to the current in commercial use. ~ Afier transferring the load, operate the engine without any load during the setting time in random and stop the engine, nF oman www. DATEGor.kr 164.3 Operation of Equipment > Check if the generator set has been maintained for operating the generator. D Check the amount of fuel tank and replenish fuel in case ofits shortage. D Check the amount of lubricant and replenish it in case of its shortage, making use of oil level gauge Exchange the contaminated oil into new one. D Check the amount of cooling water and replenish it in case of its shortage. Check the amount of lubricant and replenish i in case ofits shortage, making use of oil level gauge Exchange contaminated oil into new one. D Check the amount of cooling water and replenish it in case of its shortage. > Pour anti-freezing solution properly in winter and input current into a preheater to maintain the temperature of cooling water to 20-40'C. (In case of sticking) D Close radiator cap or expansion tank cap thoroughly by all means > Check the specific gravity and amount of electrolyte, charge it in ease its specific gravity is low and replenish iewith distilled water in case ofits shortage by all means. D Inspect if any erosion occurs on the connecting terminals, and © BK es check the connected condition and fasten it tightly. D Check the connection condition of load terminals. Bea > Check the connection condition of wing. a D Check the fastening condition ofboltsinuts on each component. QS SK Check the earth condition ofthe generator > Check iFany tool is on the generator set. a7 PnnFemuon www.DATEG.on. krHow to Operation ® Hand Type (A) Srare ~ For key switch type, put the key switch for start position, start the engine and then turn it ro the FR. ~ For toggle switch, pur the switch to start position. - For push butcon type, press start button, ~ For start-operation-stop switch type, put the switch to start position and crank switch to crank position. (After put low speed-regular switch to low speed position.) - If you cant start it, re-start it after start motor stops thoroughly. ' Cautions. Dont operate it more than 10 seconds. Start motor might be damaged. (B) Operation Take a look at oil pressure gauge if oil pressure can form after stat. In case oil pressure doesn't form, stop the engine right away and then restart it afer analyzing any cause. ~ Check if any error or breakdown for the equipment in operating it with low speed. ~ Ifany error or breakdown isn't found, adjust regular rotations with speed regulating function. (For lower-regulae speed, put it to the position of regular speed.) ~ Check if voltage gauge indicates regular voltage. In case it doese't in voltage regulator. ~ Ifany error or breakdown isn’t found after checking cach instrument, apply load. (In applying load, the load which starting current is greater can be input.) ate regular voltage, adjust it wich (© Swoppage - In stopping, block load and stop it. ~ After cooling the engine, curn the key switch to “OM” position, toggle the toggle switch to “Stoppage-star” position and, for push button type, press stoppage button. ~ For separable body-typed panel, only press push button switch. www.DATEG.or.kr 18,» Semi-auto Type (A) Manual Operation - In operating manually, put auto-manual optional switch to manual position and operate i like hand type. (B) Auto Operation » Sart ~ Put auto-manual optional switch to auto positon ~ You can state the engine after confirming if power failure occurs, distinguishing it from the power failure while electric power is given out of. ® Operation In case Hanjcon(KEPCO)’s current sources is stopped, keep rating rotations and input load to the current sources in generating power if constant voltage is confirmed to be established. (Put low-regular switch to the position of regular speed.) 9 Stoppage = If Hanjeon (KEPCO)’s current resources are supplied in generating power, transfer generated power into Hanjcon (KEPCO)’s current resources after checking its recovery condition, - Afier transferring load, operate it without load and then stop the engine. - For auto type as start-input-blocking stoppage is operated automatically, you dontt need to handle it (Do not stop generator right away except emergency) ® Auto Type (A) Manual Operation = In operating manually, put auto-manual optional switch to manual po: and operate it like hand type. (B) Auto Operation > Start ~ In operating manually, put auto-manual optional switch to manual position and operate it like hand type. ® Operation = In case Hanjeon(KEPCO)’s current sources is stopped, keep rating rotations and input load to the current sources in generating power if constant voltage is confirmed to be established. @ Stoppage - If Hanjeon (KEPCO)'s current resources are supplied in generating power, transfer generated power into Hanjeon (KEPCO)'s current resources after checking its recovery condition. ~ Afier transfersing load, operate it without load and then stop the engine. - For auto type, as start-input-blocking-stoppage is operated automatically, you don't need to handle it. (During cooling the engine) www.DATEC.or.kr® Parallel Type (A) They are generator I and II. Operate them in parallel (B) Order of parallel running ® Ifcither of the generators has load more than rating output of power, run the other generator. ® Icchecks any synchronized state between the generated current resources power under the trial input running and the generated current resources power under the standby condition of input. © If the synchronization realizes, input the circuit breaker of main circuit to run it in parallel ® Ifyou can run one of the generators due to the decrement of load in running in parallel, run the circuit breaker of ‘main circuit and stop the engine. Srp omen www.DATEC.or.kr 20=_ . 4.4 Running under Any Specific Conditions Specific conditions mean that you operate the engine under the seasons such as extreme high temperature (the hottest weather) and extremely low temperature (the coldest weather), or under the environment such as extremely sandy, humid or salty area, not under the normal conditions that you can run it casly. (A) Operation in severely cold weather @ Engine oil and fuel eo © Use engine oil for winter with low density grade (SAE). ” Use fuel with low freezing point. » Keep the fuel system away from moisture, snow, rain and ice. ® Mi the fuel with more than 20 % of a fuel additive with good fluidity which well mix with diesel fuel and fully fill the fuel tank in order to prevent condensation, ® Electric condenser » Add distilled water before starting the engine in order to protect the electrolyte from freezing ® Increase the density of the electrolyte as the electric condenser is charged. Electrolyte with density 1.2 or below will freeze at 20°C. Check if the electric condenser is fully charged in. order to prevent the electric condenser from freezing. (Ac this time, che denseyofche elecrlyte canbe 1.26 or above 2) © Low temperature will reduce the capacity of the electric condenser. Save the energy obtained from the electric condenser as far as possible and construct a facility ‘which protects the electric condenser from critical coldness (An electric condenser with frozen electrolyte can not be used), ® Check the connections and load cable of the electric condenser and prevent them from being bent. www.DATEG.or. kr® Operation © Fully preheat the inside of the engine cylinders using the preheating plugs before starting, (in case there are preheating plugs installed). © [vis dificule co start the engine frequently ina severely cold weather because the function of the electric condenser deteriorates. IF starting ean not be performed within 10 seconds, try it again after 2 minutes. [CS Perform pre-operation for a sufficient time before applying the load after starting the engine. ® After operation » Discharge water and remnant piled on in the fuel system to prevent freezing © Pally il the fuel tank to prevent it from freezing. > Operation in severely hot weather Engine oil and fuel » Use engine oil with high density grade. » Fill 2/3 of the fuel tank considering the expansion rate of the fuel. Use fuel with low freezing point. Electric condenser » The electricity of the electric condenser may be lost through self-discharge in a high \L/ temperature. Separate the electric condenser form the engine and keep it in a cool place. i » The storage should be done in a place with low temperature, dry and free from rain, © aa snow oF direct sunlight reat / | » Check he level of electrolyte of the electric condenser with a level meter © Cooling water » Always adequately fill the cooling system with cooling water. © Use fresh water as cooling water and do not use purified water of alkali sale contents © Clean off materials in the circulation route of the cooling water. » Check if che water temperature regulator operates properly. www.DATEG.or.kr 22® Operation ; : ms S Be careful to protect the engine from overheatin; ‘monitoring ” de dhermomier of cookagermen amie © 7 S S aS S ® When the engine is overheated, remove the load dowly and QQ ox drive the engine slowly in order to slowly cool down the engine. » Iris dangerous to abruprly stop the engine overheated and also 0 pour cold water to the radiator. Do not open the cap of the radiator , immediately after stopping the engine. ° (ic is very dangerous as the boiling water may be erupeed by the pressure) (©) Operation ina place with much dust or sand > Spray water around to let the ground be wet so that no dust or sand may be blown. > Clean elements of fuel filter and air cleaner. > Clean the fan cover and grill Frequently so as not to allow any oil left. > Store lubricant in a clean place. (D) Operation in a place with much salt or moisture » Always clean sale contents off as it may corrode metals. » Touch the area where painting is peeled off with approved paint. » Apply rust inhibitor to the exposed surface of metal » Always remove moisture. Put a waterproof cover over the equipment when not in use. www.DATEC.or.kr5.1 Preventive Maintenance (A) Outline To always operate the generator set, you should find and regulate any defect before the generator gets damaged or broken to check the set regularly to perform a preventive maintenance, write these contents and analyze them generally. (B) Plan for Preventive Maintenance To perform a preventive maintenance effectively, set daily, weekly, monthly and quarterly maintenance plans and perform them. Daily Maintenance © Daily maintenance has to be performed every day. Make a plan for the contents before, during and after equipment cunning. Weekly Maintenance ® Weekly maintenance has to be performed every week. Make a new plan including the contents before, during and after equipment running day by day. Monthly Maintenance » Monthly maintenance has to be performed every month. Separate it from weekly maintenance schedule. Quarterly Maintenance > Quarterly maintenance has to be performed once every 3 months. Separate it from weekly and monthly ‘maintenance schedule. (©) How to Perform a Preventive Maintenance » Peeform the preventive maintenance for inspection, cleaning and adjustment. » As the schedule of preventive maintenance has maximum interval, don‘ exceed the existing period. » Record and adjust any defect in performing a preventive maintenance through its incoming adjustment. » Ifyou solve this problem through incoming adjustment and ask for fixing or dismantle for maintenance, the related manufacturer or professional maintenance company support the matte » Inspect all the matters precisely and thoroughly. SraFvaron www.DATEC.on.kr 24www.DATEG.or.kr | Figen 1) Mh, a 2 E Poa 4 : » bok Gy 7? pon oe | aE a “oa Par Ty i. Doo ue yor, $2 bbG ge fF SP EGE er 2h ib Bi eh gp ap Hb So g be de ab aH Ss =| dau ile| -) 2) See gs 6 4 Bo saebebe5e53 a9 & OO ors) ‘S g —Seeeee aaa Be g bi) allo |) + Sees Sz 3 Bi” OW” Od US) Sees 238 4 Qf Saeeseseaes el £ ge = ico! — ne 8 poe OS a 8 25 nF oanEe araceyo eure and Breakdown Excluding 5.2 Breakdown and Its Countermeasure (A) Outline ‘When you repair any unsatisfying operational state or defect, analyze exact cause, exclude any breakdown and make all he equipments work perfectly. IFany cause for breakdown is proved, refer error excluding table in this section to fix it, Also, with watching it carefully, you can clongate lifetime of the each equipment a lot in case you find any error or breakdown before it hurts related facility seriously to take is action, @ Voltage Cause ‘Transformer Fuse Disconnection Disconnection of Winding Exciter Ci isorder © Over Voltage and Low Voltage Cause Ground Loop of Exciter Short Circuit Increased pressure of field coil caused by overload ® Vibration-non-excitement Cause Mechanical unbalance Disorder of direct connection and axis Abrasion or damage on the bearing Substance touching the Rotating Part Measure Exchange to the spare Repair by professions Measure Use a measur and measure the presure to find and repair che pare with problem Decrease overload with presire messure equipment and exciter voltage. Measure Repair by professions Exchange with the spare or repair by professions Repair by professions Remove the substance touching the rotating part is touching. www DATEG.or-kr 26me ®@ Under Vibration-Loadable Cause Defects in the motor Defects in the basic Partially Shore of the Field Coil Unbalanced load Power Line Incidents (Shore Cireuit Ground Connection) Cause Overload Short circuit of coil Ventilation Problem Low (low frequency) speed operation Superannuation @ Bearing ~ Overheating or Damage Cause Vibration occurring regularly. Overload Lack of Oil Disorder of bearing Low quality oil Disorder in oil rotating Measure Inspect repair the defect Reinforcement Repair by professions ‘Adjust the load Find the part and repair © Overheating or Damage of Electric Armature Winding Measure Decrease overload to normal Repair by professions Disassemble and locate problem Operate in normal speed Exchange Measure Repair the causes Inspect and repair Supply oil Exchange the Bearing or repair by professions Exchange oil Inspect and exchange www.DATEC.or. keEe ae CRVC rt crtt) and Breakdown Excluding @ Serious Alteration for Voltage | Cause Measure Disorder in Coil or terminal connections Repair coil or terminal connections | Disorder in exciter Repair the exciter Inferior Automatic Voltage Regulator Exchange the AVR. | Unsteady Engine Speed Adjust the speed | Immediate change of load Stable load ® Serious Alteration for Frequency ‘Cause Measure | Engine Speed is not stable Adjust the speed Inferior Frequency Meter [Exchange the frequency meter Inferior Frequency Converter Exchange the frequency converter @ Trip of Circuit Breaker | Cause Measure Inferior Circuit Breaker Exchange the circuit breaker Low Voltage Adjust the voltage Overload Adjust load @ In case engine starting motor works bur not for cranking ‘Cause Measure: Fuel is nor supplied because of the aie in Remove the air the fuel supplier parts — SrnF soe wns DATEG on ker 28cc ® Overheated Generator Canse Overload, Air is not supplied Load is not stable Disorder in the bearing Short circuited Coil or inferior insulation Measure Adjust load Ventilation equipments Adjust load Exchange the bearing Repair @ Inferiority of Engine Starting Motor in Its Operation Cause Inferior Status of a Capacitor Capacitor (Loose Cable connections or disorder in cables) Engine Controller has the capacitor switch OFF or a disorder Starter Motor wiring circuit change is loose or disorder in cables or TERMINAL Protection Circuit Trip Inferior Starter Motor ® Hunting Phenomenon of Voltage Cause E/G Rotation Speed is not stable Inferior AVR Sensibility Control Measure Inspect the Capacitor Tight cable terminal ‘Tun OFF to ON, exchange for the disorder Inspect and tight CABLE TERMINAL, exchange for the disorder Push REST BUTTON (Citeuit Switch) Exchange Measure Adjust amoune of fuels injected from the pump Adjust VR or turn VRI clock wise. Inspect and Exchange www DATEC.or.kr@ Indicator of Over-speed, Indicator of the water of high temperature and low oil pressure Cause Measure Disorder in the Relay » Over sped light Exchange the Relay » High water temperature light > Low oil pressure light Disorder in the Circuit Fix the circuit Disorder in the Stop Magnet Repair or exchange Disorder of the connection between Repair or exchange(contact an engineer) net and gar burner Inferior Gar Burner Repair or exchange(contact an engineer) @ In case the engine doesn't stop in spite of moving the switch to stop position Cause Measure Disorder of KEY S/W Repair or exchange KEY S/W. Disorder in the Circuit Fix the circuit Disorder of Stop Magnet Repair or exchange Disorder of the connection between net and gar burner Repair or exchange(contact an engineer) Inferior Gar Burner @® Protective Circuit Works under normal condition Cause Measure Disorder ofthe interlocking relay Inspect and exchange www.DATEC.or.kr 30,® Rapid ‘Temperature Increment of Engine during Run Cause Lack of the Cooling Water Inferior Fan Belt Disorder of the Cooling Surface Disorder of the Lubricating Oil Pressure Disorder of the Exhaust Pipe ‘Cannot find the cause @ Pressure Decrement of Lubricant in running Cause Disorder of the Oil Pressure Indicator ‘The lubricating oil ype licking Cannot find the cause ® Decreased Output of Power of Engine ‘Cause Overload Situation Air in the fuel pipe (Cannot find the cause Fvosscia Measure Supplement Adjust the tension or exchange Clean and remove substances Supplement ‘Clean the Exhaust Pipe or exchange Contact the engine or the factory Measure Repair or exchange Repair or exchange the oil ype Contact the engine or the factory Measure Adjust Load Remove the air Contact the engine or the factory — www DATEC. or krCause ® Unbalance of the Voltage for Each Phase Cause Measure Check load of separated phases are stable with current Inbalanced | af hi ‘Unbalanced load of separated phases switch and adjust loads to balance Voltage Switch concacts in disorder Repair ot exchange ‘Wrong terminal wiring Fix wiring (Refer to tablet) Cannot find the cause Contact the engine of the fctory ® Unbalance of the Current for Each Phase Unbalanced load of separated phases Balance load of separated phases Current Switch contacts in disorder Repair current switch or inspect current with transition Unbalanced currents of separated phases — me Measure switch to use measure for unbalanced currents : Keep in mind this! fe) 82. 41. 534. 4561 {f any problem occurs, contact us right away. Datec Maintenance Service Co. Ltd. helps you with good faith. Sng onc www.DATEG.or.ke 326. Maintenance of Generator 6.1 Maintenance of Generator (A) Explanation. ” Main generator is divided into rotator and fixer; cotator has field winding to generate magnetic electricity after receiving DC from the electromotive electron of exciting gencration, Also, it has a stator armature winding in the housing of fixer to generate electricity on the stator armature winding due to the relative interaction between magnetic flux and motion. coil. > Rotator consi of rotational shaft, feld iron core, feld coil and coupling, flexible board and cooling pan linked to an engine. Fixer consists of fixer housing, armature core and armavure e fixed and compressed, coil is inserted into the slo groove of the assembled iron core into a housing. It is connected to the terminal tube of voltage circle, » For field, several thin silicon sheets are fled up to several folds, an axis is inserted into the fixed sheets, and some field windings are winded up on the magnetic body to connect to the other wires. (B) Dismandlement » Loosen the fixed bolts connected to the flywheel housi of engine and uncie the installed bolts on a support » Making use of a hoist or lifer, keep the fixer housing on a dead level and lift ic up to the upper side. » Loosen the bolts connected to an engine flywheel and flexible tube and separate only generator components from a generator set. » Loosen the bolts and separate exciter housing. » Separate a rectifier from the axis of rotator. » Separate the bushing nuts of excites. (C) Mending, Inspection and Exchange » Inspect any cracks or breakdowns on the housing of a generator and any dust and contaminant on a fan cover. » Inspect any cracks and breakdowns of the frame of exciter. any error is Found on a component, exchange it. » Inspect the rectifier on the heat saving board, If any error is on the rectifier, exchange it. » Inspect abrasion and breakdown of bolts and nuts. Exchange any defected component. 33 Ppa Femon www.DATEC.or.kr(BEM lotta Roa eloitortcos (D) Inserting of Grease > For a generator, dress some grease on the bearing, ~ IF you want to insert some grease on the bearing, insert the grease into central the entrance of grease on the upper position of bearing cover. (E) Cleaning » Making use of the permitted water soluble powder, acquire the dismantled part and then dey it enough. » For the dust-proof rubber, don’t use any solvent and wipe ie out well with clean cloth. » Inspect whether each part might get broken or any bole hole gets broken oF not. » Inspect ifthe bolts get broken, (F) Assembling » After mending ie thoroughly, assemble the parts according to a priority, looking out for the breakdown or loss of any component. es = www.DATEC.or.kr 346. Maintenance of Generator —= . — 6.2 Maintenance of Switch box and Operation Box (A) Function and Structure » A switch box of this facility consists ofthe controlling components for operating a generator. As these deviees are installed with earth-typed electronic parts into a distinguished box, outer condition affect lite on the device. they are semi-permanent and have quick response speed. (B) Inspection and Cleaning © Inspect any breakdowns and cracks on the switch box. If any loosened part, fasten the part. » Inspect any breakdowns, cracks and erosions on each instrument. IFany loosened part, fasten the part. ° Inspect any breakdowns and aged part. Make sure whether the position of an indicator is normal or nor. > Confirm if each switch is operated well or not. » Peel out the corrosions on the switch box, wipe it out and paine it with authorized paint. © Exchange any broken instrument. IF any connected wiring gets aged or disconnected, exchange it. 6.3 Maintenance of Base (A) Function and Structure » The base for this equipment was welded and manufactured with steel materials to keep the engine and generator stable, (B) Inspection and Cleaning » Inspect any breakdowns and cracks on the welded and connected part. Also, inspect any erosion or peeled paine. » Weld the erack on the welded part. Fasten the connected part. Clean the decayed part and paint it with authorized paint. 35 SPF ewan www. DATEC.or keOPV Eth conr eRe erator tig 6.3 How to Use Storage Battery © The life time of storage battery gets differed according to the frequency of its charging or discharging. If you discharge the battery until rechargeable amount and then use the charged cycle, you can only use 200 cycles. However, if you discharge it up to 30% and then recharge it, you can use it more than 1200 cycles. Therefore, forbid over-discharging and charge it in no time when it is discharged up to 80%. Since generator for emergency (in case of auto of semi-auto type) is never discharged except for nacural discharging, i¢ is always on ‘Full Charge. You can charge it according to a regular eycle, making use of an auto charger. ® Since generator for commercial use (hand type) can be charged repeatedly up to great amount of charging by the alte- ator mounted on the engine, you had better charge it once a month in case you dont use it. ‘A. Daily Inspection and maintenance > Make sure ofthe amount of electrolyte and replenish icin deficiency. Always dry the surface and remove dust. > In case the terminals become degraded or oxidized, remove the oxidized matter and apply non-metallic grease thinly. > Avoid a direc ray of light and keep it ar the dried and normal temperature applied place. In case ofits keeping, charge it once a month, Sen F ewan wn DATEG. on.kr 366. Maintenance of Generator = a 6.4 Safe Operation ‘¢ You shouldn't perform live-wire operations in principle. Especially, you shouldn't do ‘that except for any admitted condition. © In working without turning on the switch, check the electricicy without fail, confirm if the electricity doesn‘ run, short the switched-off circuit and earth it. Even if the electricity ine is opened, itis to block any disaster due to any mistake such as induction or mingle with a converter. Also, when you connect the earthed line to a converter, you should do it first on the ground part. In separating it, you should do it frst on the converter part. This is to block the electricity to go through the body. © In working without turning on the switch, lock it with a circuit breaker and indicate the prohibition of sending an electric current. you should make any countermeasure not to applying the current. © Dorit deal with self electronic devices except forthe elecric relating expert or company. ‘e Ifany indication such as “Nor Allowed? in sending the current, observe this indication. ‘© Don't operate any electronic equipment when you get wet. ‘© High-tension electricity is very dangerous even though you just approach ie. For proximal activation work, follow the charger’ directives. Especially, you should be more careful at an isolated place from the work place. Also, make sure if you leave any panel board and tools such as driver or bench into the equipment. 37 Sr F oman wa. DATEG.onkeDATEG www.DATEC.or.kr 160-2 Banghyun Ri, Yeomchi Eup, Asn Si, Chungnam 336-814, Korea tel.(82) 41. 534.4561 2)/fax. (82) 41. 534. 4564 / wwwedatecorke