Generator Manual PDF - Removed

Prepared By Melan Electromechanical Solu on PLC
Part - I
Generators Manual
4|Page
1. Diesel Generators (Generalities)
DG Block Scheme:
Diesel Generator Set
2. Diesel Engine Main Components
DG Main Components:
5|Page
DG Engine
DG Engine Main Parts
6|Page
Engine Stroke -1
1. Intake: Also known as suc on. This stroke of the piston begins at top dead centre (T.D.C.) and ends
at bo om dead centre (B.D.C.). The intake valve must be in the open posi on while the piston pulls
into the cylinder, the piston is moving down as air is being sucked.
Engine Stroke - 2
2. Compression: This stroke begins at B.D.C, or just at the end of the suc on stroke, and ends at
T.D.C. In this stroke the piston compresses the air in prepara on for injec on during this stroke Both
the intake and exhaust valves are closed.
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Engine Stroke-3
3. Power: Also known as power or igni on. This is the start of the second revolu on. At this point the
cranksha has completed a full 360-degree revolu on. While the piston is at T.D.C. (the end of the
compression stroke) the compressed air-fuel mixture is ignited by heat generated by high
compression diesel engines, forcefully returning the piston to B.D.C. This stroke produces mechanical
work from the engine to turn the cranksha .
Engine Stroke-4
4. Exhaust: Also known as outlet. The piston, once again, returns from B.D.C. to T.D.C. while the
exhaust valve is open. This ac on expels the spent air-fuel mixture through the exhaust valve. The
stroke produces mechanical work from the engine to turn the cranksha .
DG Engine Auxiliary Systems
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1. Fuel System
The First part in the fuel system is the Fuel Water Separator (FWS).
This is a primary filtra on unit used to remove the water from the diesel fuel before it reaches to the
sensi ve parts of the engine. Water and contaminants have a direct impact on the service life and
performance of diesel engines.
To remove the water from the Fuel Water Separator, the operator should periodically check the
primary Filter and open the valve to drain the water. The FWS’s have different sizes and
configura ons based on the flow rate required by the engine fuel system
The use of a suitable filtra on system on diesel engines is a must to avoid damage to closely fi ed
injec on pump and injectors.
On diesel engines primary and secondary filters are used. The primary filter can remove dirt
par cles down to 30 microns and the secondary filter between 10 to 12 microns.
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Injector
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Fuel System: Mechanical Governor
A classic example is the centrifugal governor, also known as fly-ball. (Flyweights) governor on a
reciproca ng Diesel engine, which uses the effect of iner al force on rota ng weights driven by the
machine output sha to regulate its speed by altering the input flow of Diesel.
Governors serve three basic purposes:
1. Maintain engine speed within the range of the governor.
Example 1500or 1800 RPM
2. Prevent over-speed which may cause engine damage.
3. Limit both high and low speeds.
Fuel System: Electrical Governor
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2. Lube Oil System
The lube oil system lubricates the rota ng and moving parts and gears of the engine to minimize the
effects of metal-to-metal contact that causes both sliding and rolling types of fric on, and to absorb
great amount generated heat to achieve smooth performance of the internal parts of the engine.as a
resume,
Oil system has three func ons:
 Cleaning
 Lubricating
 Cooling
Oil Pump is gear-driven pump. It pulls oil from the lube oil pan (sump) and supplies it to the engine
when the engine is running.
Typical oil pump consists of:
 Gear pump
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 Driving gear
 Pump housing.
Oil Filters
They receive the oil from the pump. The filters clean the oil and remove any metal par cle that the
oil has picked up, to remove it from the circuit before it goes to the engine bearings or inside the
cylinder block.
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3. Cooling System
Diesel engines are heat-genera ng sources. They are cooled by circula ng a water-based coolant
through a water jacket, which is part of the engine. The coolant is circula ng through pipes to the
radiator to remove the heat added to the coolant by the engine and then goes back to the engine.
Proper ven la on is required to cool the engine for achieving the op mal performances.
NEVER RESTART AN OVERHEATED ENGINE UNLESS THAT OVERHEATING CAUSE IS REMOVED
1. Water pumps
2. Heat removing device (radiator or heat exchanger)
3. Coolant expansion tanks (surge tanks)
4. Temperature control valves (thermosta c control valves)
5. Temperature and pressure switches and indicators
6. Manifold / Pipes
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Turbo Charger Engine
It is important to ensure that air temperature does not become excessive in modern boosted engines
as the Excessive air temperatures in the air intake manifold can reduce the charge-air density and
higher combus on temperatures which can affect efficiency and emissions.
That is the main reason to implement the Double Loop cooling system and Air to Air cooling system
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Radiator: The radiator is an air-cooled heat exchanger. It consists of an inlet box and a discharge box
connected by many small diameter tubes arranged so that the air flows through the tube. The tubes
have fins on the outside surfaces to enhance the heat transfer between the tube surface and the
cooling air.
• Fan: Standard gensets have engine-driven fans . The func on of the fan is to blow air at the
required flow density to cool the radiator
GENSET APPLICATION
MOBILE APPLICATION
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The boiling point of water at atmospheric pressure (1 Bar) is 100oC, however the boiling point is
changing with pressure, this graph is showing the boiling point of water at different pressures.
At boiling point the temperature stops rising and water stops absorbing the heat. The temperature
will not rise further un l all the water has evaporated.
To increase the heat generated by the engine block, we have to increase the boiling point, this can be
achieved by increasing the cooling circuit pressure=> this is the role of the radiator cap.
NEVER OPEN RADIATOR CAP OF A RUNNING, HOT OR OVERHEATED ENGINE
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4 & 5. Air Intake & Exhaust System
• The turbo charger consists of two turbines on one sha . The first turbine is known as the hot
turbine is driven by the hot gases.
• The combus on gases have high pressure and high speed enough to produce enough torque
to drive the hot turbine to a very high speed. The high-speed rota on of the hot turbine
causes the other turbine to rotate at the same speed. The second turbine is called the cold
turbine It is completely isolated from the hot turbine and installed in different housing.
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6. Star ng System
• It mainly consists of star ng ba eries sized enough to run an electrical starter motor to
Ini ate and achieve rapid engine rota on and reach fuel firing speed, the starter motor is
deac vated once engine self-rota on is being established due to the engine internal firing /
compression
The crank is disconnected if:
• Engine speed / frequency built up
• Oil pressure reached predefined value
• Voltage is built up
• Starter mer reached the limit
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3. Alternator
AC Generator and Excita on Control
Alternator is the component which converts the mechanical power provided by the engine to
electrical power
The alternator can be characterized by the following Data:
• Prime & Standby Capacity (KVA)
• Frequency
• Number of phases & Rated Voltage (127/220, 220/380, 230/400…)
• Power Factor: Typically, 0.8 For all alternators.
• Excita on method (Shunt, PMG. MAUX…).
• Winding & leads (6 or 12 Leads)
• Insula on and Temp rise class
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Star ng:
Voltage:
Over Voltage:
Normal Voltage:
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Excita on System
MAUX:
The MAUX uses the output voltage of the main stator as supply voltage and a single auxiliary winding
inserted in selected slots of the main stator for booster effect. The combina on of these two sources
is then used to power the regulator, thus combining the power of a tradi onal SHUNT system with
the reliability and control level of MAUX system. Under the same condi ons, more power is taken to
supply the regulator, which improves the excita on capabili es.
SHUNT
In SHUNT excita on systems, the AVR power supply and voltage reference are picked on the same
output terminals. The AVR generates and regulates the excita on current as a func on of the
alternator output voltage.
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The SHUNT system is extremely simple in its design and is ideal for standard applica ons.
Excita on System: PMG
AREP/MAUX:
The new AREP+ uses the output voltage of the main stator as supply voltage and a single auxiliary
winding inserted in selected slots of the main stator for booster effect. The combina on of these two
sources is then used to power the regulator, thus combining the power of a tradi onal SHUNT
system with the reliability and control level of an AREP system. Under the same condi ons, more
power is taken to supply the regulator, which improves the excita on capabili es
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Control System – PMG
Excita on System: PMG
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Alternator Main Component
Alternator AVR Component
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Alternator Leads
4. Engine Controller & Monitoring

AC03 Controller
• Single genset operating in standby or prime power modes
• Full gen-set monitoring and protection
• 3 phase power measurement of gen-set and mains incl. kWh
• Engine ECU support with diagnostic messages in plain text via J1939
• Detailed event and performance log with time and date
• Earth fault current protection*
• Alternative switchable configuration
• Automatic and manual GCB and MCB control
• Magnetic pickup input
• D+ pre-excitation terminal
• 3 configurable analog inputs
• 7 binary inputs
• 7 binary outputs
AC03 Controller
START button. Works in MAN mode

only. Press this button to initiate the
start sequence of the engine.
STOP button. Works in MAN mode

only. Press this button to initiate the
stop sequence of the gen-set.
Repeated pressing for direct stop
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FAULT RESET button. Use this

button to acknowledge alarms and
deactivate the horn output. Active
alarms will be changed to
"confirmed" so they will disappear as
soon as their reasons dismiss.
FUEL PUMP button. While this button is

pressed FUEL PUMP is activated until
Fuel Pump OFF level is reached.
MODE LEFT button. Use this button to

change the mode. The button works only
if the main screen is selected
MODE RIGHT button. Use this button to

change the mode. The button works only if
the main screen with the indicator of
currently selected mode is displayed.
GCB button. Works in MAN and TEST modes

only. to open or close the GCB manually.
Note that certain conditions must be valid
otherwise GCB closing is blocked.
MCB button. Works in MAN and TEST modes
only. Press this button to open or close the
MCB manually.
PAGE button. Use this button to switch over

display pages. See Display Screens and Pages
Structure chapter below this table for more
details.
Gen-set failure. Red LED starts flashing when gen-set failure
occurs. After FAULT RESET button is pressed, goes to steady
light or off (if no alarm is active).
Gen-set voltage OK. Green LED is on if the generator
voltage is present and within limits.
GCB ON. Green LED is on, if MCB is closed.
MCB ON. Green LED is on, if MCB is closed.
Mains failure. Red LED starts blinking when the mains
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failure is detected and after the genset has started it
lights permanently until the mains failure disappears.
5. Generator Control System

AC03 Controller
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Communication Port
1- Current measurements
2- Generator voltage
4- Binary inputs
3- Mains voltage Gen and Mains

Volt
5- CAN bus and RS485 6- Analog inputs
8- Binary Outputs
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7- Power Supply
Plug in modules:
Local
IL-NT RS232
IL-NT RS232-485
IL-NT S-USB
Remote
IB-Lite
IL-NT GPRS
Bridge modules:
I-LB+
Internet Bridge-NT
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Communication Port
IL-NT USB
IL-NT RS232
To connect your PC to the AC03 unit you need the following RS232 Cross-Wired Cable (female-
female)
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6. Trouble shooting
AC Alternator
NO VOLTAGE (NO LOAD)
 Voltmeter connected incorrectly, or faulty.

 Loose broken or corroded connections / Breaker.
 Very low insulation resistance to earth (ground), on exciter.
 Alternator Not Rotating
(Broken Coupling Bolts.)
 Engine speed low. Under frequency protection (UFRO) circuit activated.

 AVR 'VOLTS' adjust, or external hand trimmer control incorrectly set.
 Fault on power supply from main stator.
 Fault in AVR.
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HIGH VOLTAGE (NO LOAD)

 Sensing supply from Main Stator to AVR open circuit or too low.
 AVR 'VOLTS' control or hand trimmer incorrectly set.
 AVR faulty.
UNSTABLE VOLTAGE (NO LOAD)
 Engine speed 'hunting' (unstable).

 AVR stability control incorrectly adjusted.
 Loose or corroded connections.
 Intermittent earth on machine
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UNBALANCE VOLTAGE (NO LOAD)

 Single-phase load current unevenly distributed over the three phases.
 Main Stator winding insulation issues in one or more phases.
Diodes Testing – Digital Multimeter

A Diode has two resistance values, forward and reverse, these can be measured with a multimeter as
shown in the diagram. An arrow printed on the diode body identifies the positive side of a diode. The
forward resistance is being measured in Fig. A with the positive meter lead connected to the forward
side of the diode. In Figure 'B' the meter leads have been reversed, and the reverse resistance is
being measured.
A faulty diode will give a reading in both forward and reverse directions (short circuit), or no reading in
either direction, (open circuit).
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7. Health, Safety and Installation

SAFETY FIRST
General Hazard
1. Installation, repair and maintenance should always be in accordance with the
manufacturer’s instructions and recommendations.
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2. Exhaust fumes emitted by generator sets contain poisonous gases like carbon
monoxide that can be life threatening and result in death. Exhaust systems must be
properly installed, adequate ventilation must be provided to ensure unobstructed flow of
cooling and ventilating air, and emissions must be directed away from inhabited zones.
3. The area around the generator must be clean and free of clutter and any combustible
material that can be hazardous.
4. The equipment must be regularly inspected and defective or damaged parts must be
replaced in a timely manner.
5. It is essential that the operating personnel always remains alert while working with the
generator.
6. The unit should not be opened or dismantled while it is functioning. Moving or hot
parts should not be tampered with. Battery cables should be disconnected before
proceeding to work on the generator to eliminate any possibility of an accidental start
up.
ELECTRICAL HAZARD
1. All power voltage supplies should be turned off at the source while installing or servicing the
generator.
2. All electrical connections, such as wires, cables and terminals must be properly insulated and
covered, and should not be touched with bare hands or while in contact with water. This is
essential to prevent the occurrence of an electric shock.
3. The frame of the generator and any external conducting parts should have proper grounding /
earthing wiring. This should never be disconnected.
4. Wiring, cable and cord sets must be of the recommended capacity.
Fire and Explosion Hazards
1. Smoking in the vicinity of the equipment can be fatal.
2. Fuel or oil spills around the generator, leakages from the unit’s fuel system and fuel supply
lines and presence of combustible materials around the generator will pose a risk of an
explosion.
3. A fire extinguisher should be readily available. Use of extinguishers that operate on carbon
tetra-chloride is strictly prohibited since the fumes are toxic and can deteriorate the insulation
on the wiring of generators.
Installation
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Installation Procedures
1. Equipment should always be installed, serviced and repaired only by Authorized Service
Dealers, or competent, qualified and certified technicians.
2. Personal should have a thorough knowledge of and always comply with standard operating
procedures, applicable codes and regulations.
3. It is essential to check whether the generator and its accessories comply with the latest
version of any standards as applicable to the equipment.
4. Upon unpacking the generator from shipping cartons, first conduct a thorough inspection to
detect any damage that may have occurred during shipment.
5. Check whether the rated capacity of the unit is adequate to handle all the intended loads
during a power outage.
6. If required, the critical loads may be grouped together and wired independently into an
exclusive distribution panel.
7. The generator should be installed in close proximity to the location of the transfer switch and
the fuel supply, to reduce the required length of cabling and piping respectively.
8. You may be required to seek a permit if you intend to store a large fuel tank. The fuel pipe
sizing, construction and layout must comply for liquid propane applications.
9. A grounding lug is usually provided for grounding the frame and external conducting parts of
the equipment.
10. It is essential to consult a qualified electrician to determine grounding requirements and
follow procedures that meet local regulations.
11. All batteries must be completely charged before they are inserted into the generator.
12. Similar care must be ensured while unpacking and installing the transfer switch.
13. The switch should be wall-mounted or Stand alone and all the points must be in level with
each other to prevent distortion of the switch.
14. The unit should be connected to the electrical system supplied by the utility only by means of
the automatic transfer switch. This will ensure isolation between the generator’s electric
system and the utility distribution system.
15. Also, back-feed can occur wherein an improperly connected generator begins to feed
electricity back into the power lines which will damage the unit and cause injury or death to
the operating personnel.
16. In the absence of a transfer switch, the safest option is to plug the essential appliances
directly into the generator.
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8.Operation and Maintenance

Maintenance Interval
Note Should Be In Mind:

 A good maintenance program is the key to long all electro mechanical system.
 Records of maintenance work should be kept to aid in developing an efficient maintenance
program.
 Generator set should be kept clean.
 Do not permit liquids such as fuel, or oil films to accumulate on an internal or external surface
or on under or around any acoustic material.
 Do not use flammable solvents for cleaning purpose.
Agency Representative: ________________

(Signature)
Location:
Date: ________________
Hour Meter:
Unit Mfg.
Model:
S/N: :
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Engine Mfg:
Model:
S/N: :
Gen. Mfg.
Model:
S/N:
Name___________________________
Time: _______________________
SECTION A – COOLING SYSTEM SAT. UNSAT.

(check one)
1. Engine coolant level
2. Radiator core/heat exchanger
3. Coolant lines/connections/hoses & connections
4. Water jacket heater(s)
SECTION B – D.C. ELECTRICAL SYSTEM SAT. UNSAT.

(check one)
1. Battery(s) electrolyte level/specific gravity
2. Battery compartment/heater cooperation
3. Battery connections/cables/casing
4. Shutdown mechanisms
5. Electrical starter/alternator generator
6. Electrical system, accessories & components
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SECTION F – LUBRICATION SYSTEM SAT. UNSAT.

(check one)
1. Engine oil level
2. Engine oil change
3. Engine oil filter change
4. Engine oil sample for analysis
5. Crankcase pressure
6. Crankcase breather
7. Oil leaks (hoses, connectors)
8. Engine governor oil level/linkage (UG8)
9. Fan drive bearings
10. Generator bearings
11. Engine starter oiler (air type only)
12. Gauges and safety mechanism
13. Accessory drives
SECTION G – FUEL SYSTEM SAT. UNSAT.

(check one)
1. Fuel tank/day tank
2. Fuel filters-primary/secondary
3. Fuel system components/hoses/piping
4. Gauges and Safety mechanism
5. Condensation/water in fuel
STARTING SYSTEM
 Check battery electrolyte level and top off.
 Never add undiluted sulphuric acid to a battery.
 The electrolyte level should be covering the plate (13mm) with the battery to
maximize full charging transfer
 Adding of extra acid destroy the grids
 Check and record battery voltage
 Check and record battery charger amperage
 Check battery connection terminals and clean as necessary
 Clean battery posts and terminals
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 Check battery charger and adjust float rate (if necessary
Lubrication System
 Check crankcase oil
level and top up, if necessary,
with the same type of oil.
 Visually inspect oil
 for contamination by fuel water or glycol.
 Visual inspection of front & rear crankshaft seals and lubrication system
gaskets for leaks
 Check for excessive crankcase blow by with engine running
COOLING SYSTEM
 Inspect engine belts for fraying and cracking
 Check jacket water heater(s) for proper operation and adjust thermostat
settings as needed
 Check and adjust belt tension if necessary
 Inspect hoses for cracking, leaking, and pliability
 Check and record engine coolant antifreeze protection
FUEL SYSTEM
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 Check level of main storage tank

 Test day tank pump for proper operation
and level
 Inspect fuel lines for leaks or cracking
 Drain water from fuel separator
 Check fuel injection and transfer pumps for proper operation and leaks
 Drain water from water separator and fuel tank
 Check governor linkages, and oil level if applicable
 Check and record level in main fuel tank
AIR INDUCTION AND EXHAUST SYSTEM

 Inspect air filter for deterioration and plugging
 Check inlet and discharge louvers for proper operation with engine
running and stopped
 Inspect air intake piping for leaks and possible dirt entry
 Inspect flexible exhaust couplings for cracks & excessive leakage
 Inspect exterior of exhaust manifolds for oil/fuel slobbering (signs of
wet stacking)
 Inspect exhaust silencer for deterioration
ENGINE MOUNTINGS
 Inspect generator set vibration isolators and adjust as needed
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CONTROL PANEL
 Operational check of warning and fault lamps
 Check proper operation of engine and generator monitoring displays
with engine running
 Adjust governor control for optimum performance and frequency
 Adjust voltage regulator for proper voltage
 Check remote annunciator for proper operation (if applicable
AUTOMATIC TRANSFER SWITCH

• Check Operation of Transfer Switch
• Transfer Building Load to Generator, Check Operation of Transfer
Switch
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Prepared By Melan Electromechanical Solu on PLC

1. Diesel Generators (Generalities)

Diesel Generator Set

2. Diesel Engine Main Components

DG Engine Main Parts

DG Engine Auxiliary Systems

Fuel System: Mechanical Governor

Governors serve three basic purposes:

1. Maintain engine speed within the range of the governor.

Example 1500or 1800 RPM

2. Prevent over-speed which may cause engine damage.

3. Limit both high and low speeds.

Fuel System: Electrical Governor

2. Lube Oil System

Oil system has three func ons:

Typical oil pump consists of:

NEVER RESTART AN OVERHEATED ENGINE UNLESS THAT OVERHEATING CAUSE IS REMOVED

2. Heat removing device (radiator or heat exchanger)

3. Coolant expansion tanks (surge tanks)

4. Temperature control valves (thermosta c control valves)

5. Temperature and pressure switches and indicators

Turbo Charger Engine

NEVER OPEN RADIATOR CAP OF A RUNNING, HOT OR OVERHEATED ENGINE

4 & 5. Air Intake & Exhaust System

The crank is disconnected if:

• Engine speed / frequency built up

• Oil pressure reached predeﬁned value

• Starter mer reached the limit

The alternator can be characterized by the following Data:

• Prime & Standby Capacity (KVA)

• Number of phases & Rated Voltage (127/220, 220/380, 230/400…)

• Power Factor: Typically, 0.8 For all alternators.

• Excita on method (Shunt, PMG. MAUX…).

• Winding & leads (6 or 12 Leads)

• Insula on and Temp rise class

Excita on System: PMG

Control System – PMG

Excita on System: PMG

Alternator Main Component

Alternator AVR Component

4. Engine Controller & Monitoring

START button. Works in MAN mode

STOP button. Works in MAN mode

FAULT RESET button. Use this

FUEL PUMP button. While this button is

MODE LEFT button. Use this button to

MODE RIGHT button. Use this button to

GCB button. Works in MAN and TEST modes

PAGE button. Use this button to switch over

5. Generator Control System

3- Mains voltage Gen and Mains

5- CAN bus and RS485 6- Analog inputs

 Voltmeter connected incorrectly, or faulty.

 Engine speed low. Under frequency protection (UFRO) circuit activated.

HIGH VOLTAGE (NO LOAD)

UNSTABLE VOLTAGE (NO LOAD)

 Engine speed 'hunting' (unstable).

UNBALANCE VOLTAGE (NO LOAD)

Diodes Testing – Digital Multimeter

7. Health, Safety and Installation

4. Wiring, cable and cord sets must be of the recommended capacity.

Fire and Explosion Hazards