container generating set - bredenoord

GENERATING SET1020981

User manual

500 kVA

EN (translation of original manual) V1.0

© Bredenoord 2020

CAUTION

• Everyone responsible for operation must at least fully read and understand the operation

and safety sections of these operating instructions.

• Everyone responsible for assembly, installation, maintenance and/or repair must read

and understand this manual.

• The user is responsible for the interpretation and use of this manual in all

circumstances. If you have any questions about the correct interpretation, please

contact the supervisor or the rental company.

• This manual must be kept near the machine and must be within easy reach of the users.

• Always observe the safety requirements, as stated in the Safety chapter.

• The correct operation and safety of the system can only be guaranteed if the

recommended maintenance is carried out on time and correctly.

NOTICE

• All the major maintenance work, adjustments to the machine and any comments must

be recorded in a logbook. This applies to persons who are authorized to perform them.

• Changes to the installation/machine are not permitted without the manufacturer's prior

written approval.

• Contact the manufacturer for special maintenance work not included in this manual.

INFO Details in illustrations in this manual may differ from those in your machine.

Copyright © Bredenoord B.V.2020.

This operating manual has been approved by Bredenoord (translation of original manual).

Bredenoord B.V. reserves the right to change specifications and/or spare parts without prior notice.

The content of this user manual is also subject to change without notice.

For information on settings, maintenance work or repairs not covered in this user manual, please contact your manufacturer's technical service.

Bredenoord B.V. accepts no liability for damage and/or problems arising from the use of spare parts not supplied by Bredenoord.

This user manual has been compiled with the utmost care. Bredenoord B.V. accepts no liability for any errors in this manual and/or for the consequences of

incorrect interpretation of the instructions.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic,

mechanical, photocopying, or otherwise, without the prior written permission of Bredenoord. This also applies to the accompanying drawings and diagrams.

Introduction

This is the user manual of the 500 kVA Bredenoord generating set. This manual is intended for

everyone who operates the generating set and performs first-line maintenance.

The illustrations in this manual may differ from the actual situation.

We recommend that you read this manual carefully before use and strictly follow the procedures

and instructions. This will ensure that you get the most out of the unit and that possible accidents

and serious injuries are prevented.

Documentation set

The following documents are available from Bredenoord B.V. and can be supplied to you on

request:

• Electrical diagrams

• List of wear parts

• Instruction booklet for the engine

• Instruction booklet for the generator

Storage of the manual

Keep this manual close to the generating set and ensure that all operators can consult it if

necessary.

The manual is also available in digital format and can be downloaded via the QR code on the

sticker in the control compartment.

Limitations of this manual

The Dutch version of the manual is the original version. This [Dutch] version has been checked by

Bredenoord. All versions of the manual in other languages are translations of the original Dutch

manual.

This document contains useful and important information for the correct installation and operation

of the generating set. This document also contains instructions to prevent possible injuries that

may occur during operation of the generating set. We have done everything possible to ensure that

this document is as correct and complete as possible. Please report any errors or inaccuracies

you may find in this manual to Bredenoord as quickly as possible. This allows us to improve our

documentation.

Version history

During the life of the machine, innovations and improvements may lead to the desire to make

changes to this document. It is up to Bredenoord to determine whether this leads to a new revision.

The table below shows the version numbers, dates and changes for this document.

Version Date Changes

1.0 March 2020 First version

Contact details

Bredenoord B.V.

Zutphensestraat 319

7325 WTApeldoorn

00800-55008800

[email protected]

https://www.bredenoord.com

Liability

Read the operating instructions carefully before operating the generating set.

Bredenoord accepts no liability for damage caused by:

• failure to follow the instructions described in these operating instructions.

• modifications or repairs to the generating set without prior written approval from Bredenoord.

• operation of the generating set other than as described in the operating instructions.

• use of non-standard spare parts and accessories.

Warnings used in this manual

The following symbols are used for all actions that compromise the safety of the user and/or

technician and require caution:

DANGER

Warns of a hazardous situation which, if the safety instruction is not followed, will result in

serious injury or even death and possible damage or serious damage to the generating set.

WARNING

Warns of a hazardous situation which, if the safety instruction is not followed, may result in

serious injury or even death and damage or serious damage to the generating set.

CAUTION

Warns of a hazardous situation which, if the safety instructions are not followed, may result

in slight or minor personal injury and may cause damage to the generating set.

NOTICE

Gives important background information on the prevention of damage or serious damage to

the generating set.

INFO

Gives an extra explanation or information that will be of use when carrying out a task.

Abbreviations and termsThe following abbreviations and terms are used in this manual:

AC Alternating current

Generating set Bredenoord 500 kVA container generating set

CAN bus Controller Area Network (communication system between components)

Controller Generator set’s central control unit

dB(A) Weighted unit of noise intensity

DC Direct current

Rotating field Rotating magnetic field

First line maintenance The work that the consumer carries out independently to ensure that the

generating set functions properly

GCB Generator master switch Generator Circuit Breaker

kVA kilovolt Ampere

LWA Sound capacity level (in dB(A))

MCB Mains master switch (Mains Circuit Breaker)

Wear parts Parts subject to wear during use, such as V-belts and alternators.

Feet or ft Unit of length (304.8 mm)

Table of contents

1 The Bredenoord 500 kVA container generating set............................................................... 10

1.1 Intended use.........................................................................................................................10

1.2 Changes............................................................................................................................... 11

1.3 Technical data...................................................................................................................... 12

1.4 Nameplate and specification sticker.....................................................................................13

2 Description..................................................................................................................................14

2.1 Main components, external.................................................................................................. 14

2.2 Main components, engine and generator compartment...................................................... 15

2.2.1 Engine liquids access door.......................................................................................... 16

2.2.2 Access door to battery and coolant room....................................................................18

2.3 Main components, cooling and fuel compartment............................................................... 19

2.4 Main components, control compartment..............................................................................23

2.4.1 Master switch................................................................................................................23

2.4.2 Distribution switches.....................................................................................................25

2.4.3 Connection points for power output............................................................................. 26

2.4.4 Control panel................................................................................................................ 26

2.4.4.1 Messages on the display......................................................................................27

2.4.4.2 Mode selector switch............................................................................................28

2.4.4.3 Interior...................................................................................................................29

2.4.5 Overcurrent protection, temperature control and generator measuring voltage........... 29

2.4.6 Auxiliary power supplies...............................................................................................31

2.4.7 Master switch with three pole or four pole switching....................................................31

2.4.8 Earthing system (TN / IT).............................................................................................32

2.4.9 Fuel supply................................................................................................................... 34

3 Safety...........................................................................................................................................35

3.1 General safety instructions...................................................................................................35

3.1.1 Mechanical hazards......................................................................................................36

3.1.2 Electrical hazards......................................................................................................... 36

3.1.3 Hot surfaces................................................................................................................. 37

3.1.4 Sound pressure level....................................................................................................37

3.1.5 Vibration........................................................................................................................37

3.1.6 Working environment....................................................................................................37

3.1.7 Maintenance................................................................................................................. 37

3.2 Warnings during use............................................................................................................ 38

3.3 Personal protective equipment.............................................................................................38

3.4 Standard safety features...................................................................................................... 39

3.4.1 Emergency stop system...............................................................................................39

3.4.2 Battery switch............................................................................................................... 41

3.4.3 Pictograms on the machine......................................................................................... 41

3.5 Safe state............................................................................................................................. 44

4 Placement....................................................................................................................................45

4.1 Opening access door........................................................................................................... 46

Table of contents 7

5 Installation...................................................................................................................................47

5.1 Connecting main power cables............................................................................................47

5.1.1 Connecting plug connector...........................................................................................47

5.1.2 Connecting cable eye bolt connection......................................................................... 49

5.2 Connecting external controller............................................................................................. 51

5.3 Connecting a number of generating sets.............................................................................52

5.4 Connecting earthing............................................................................................................. 52

5.5 Connecting the fuel tank...................................................................................................... 53

5.6 Bleeding the fuel lines..........................................................................................................54

5.7 Connecting the engine heater..............................................................................................56

6 Starting up.................................................................................................................................. 57

6.1 Checking oil level................................................................................................................. 57

6.2 Checking automatic oil top-up system................................................................................. 58

6.3 Checking coolant level......................................................................................................... 59

6.4 Safety switch for cooling fan................................................................................................ 59

6.5 Checking fuel cock position................................................................................................. 60

6.6 Checking fuel level............................................................................................................... 61

7 Operation.....................................................................................................................................62

7.1 Manual operation..................................................................................................................62

7.1.1 Starting......................................................................................................................... 62

7.1.2 Stopping........................................................................................................................63

7.2 Automatic operation..............................................................................................................64

7.2.1 Starting......................................................................................................................... 64

7.2.2 Stopping........................................................................................................................66

8 Putting out of operation............................................................................................................67

8.1 Disconnecting main power cables........................................................................................67

8.1.1 Disconnecting plug connector...................................................................................... 68

8.1.2 Disconnecting cable eye bolt connection..................................................................... 69

8.2 Disconnecting external control............................................................................................. 70

8.3 Disconnecting the engine heater......................................................................................... 70

9 Maintenance and service.......................................................................................................... 71

9.1 Scheduled service................................................................................................................71

9.2 Daily maintenance................................................................................................................71

9.3 Top up the oil....................................................................................................................... 72

9.4 Topping up coolant...............................................................................................................73

10 Troubleshooting....................................................................................................................... 75

10.1 Alarm status on controller..................................................................................................75

10.2 Master switch error status..................................................................................................77

10.3 Troubleshooting.................................................................................................................. 78

Annexes.......................................................................................................................................... 81

List of buttons and switches.......................................................................................................81

Table of contents 8

Connection strip contact points..................................................................................................82

Maintenance record plate...........................................................................................................84

EC Declaration of Conformity.....................................................................................................85

Table of contents 9

1 The Bredenoord 500 kVA container generating set

The Bredenoord500 kVA generating set consists of a diesel engine that drives a generator. The

generator is equipped with an internal diesel tank and is therefore able to operate autonomously

for a certain period of time. It is also possible to connect the unit to an external fuel tank. The

generating set can be expanded with various options if so required.

1.1 Intended use

The Bredenoord 500 kVA generating set is a diesel engine driven generator intended for the

generation of electrical power.

The power consumer can easily be connected to the generator set with Powerlock connectors.

Consumers can also be connected using conventional cable eye bolt connections.

The generating set is equipped with various protection systems with automatic signalling and a

disconnection function.

All Bredenoord components for external control can be easily connected using a 24-pin connector.

Terminal strips are provided for the connection of other external control instruments.

A number of generating sets can be linked by a CAN-bus for load-sharing purposes.

The Bredenoord 500 kVA container generating set 10

The generating set is intended exclusively for use as a power supply. All other uses are considered

by the manufacturer to be improper use and are therefore prohibited.

As the generating set requires fresh air and emits hot exhaust gases it may only be operated

outdoors.

1.2 Changes

No changes to the generating set may be made without written permission from Bredenoord B.V. .

WARNING Changes to the generating set can result in serious injuries and can cause

damage to the generating set, the consumer connected to the set and the environment.


1.3 Technical data

Description Value

Generating set number See the BR number on the nameplate

Fuel Diesel oil; during winter use winter diesel oil

Lubricants Good quality, brand name oil for heavy-

duty diesel engines. See engine manual for

specifications. Filled with Shell Rimula R6 LM

10W-40 at time of delivery.

Dimensions L * W * H 6058×2438×2588 mm

Weight net/gross 11320/13380 kg

Sound pressure level (LWA) 91 dB(A)

Ambient temperature < 25 ˚C

Engine brand Scania

Engine type DC16 071A

Serial number See the nameplate on the engine

Generator brand Leroy Somer

Generator type LSA 47.2M8

Serial number See nameplate on the generator

Connection voltage/frequency 231/400 V / 50 Hz

254/440 V / 60 Hz

Power 500 kVA

Net power 400 kW

Max. step load 50 %

Battery 2× 12 V 95 Ah

Tank capacity 2440 litres

Consumption at 75% load 109.5 litres/h

Pre-filters, fuel 1518512

Filters, fuel 2021049

Filters, engine oil 2057893

Filters, air 1931042

Belts, fan n/a

Belts, alternator 2157027

Belts, water pump combined


1.4 Nameplate and specification sticker

Nameplate

The nameplate is attached to the engine liquids access door. The nameplate gives the following

information:

1. Contact details

2. Type

3. Number

4. Weight

5. Year of construction

Specification sticker

The specification sticker is located in the control compartment, next to switch F4. This sticker gives

the following information:

1. Serial number

2. Gross weight (including

fuel)

3. Ambient temperature

4. Performance class

5. Rated frequency, voltage

and current

6. Tank capacity plus

measurement data

7. Altitude above sea level

8. Rated power

9. Year of construction

10. Standard


2 Description

2.1 Main components, external

The generating set is housed in a 20 ft container. The housing protects the mechanical and

electrical components against weather influences, dirt and damage. The housing also provides

sound insulation and contributes to the safety of the operator. The housing has a number of doors

that give the operator access to the most important controls.

INFO The access doors for the maintenance of the engine, generator and cooling may

only be used by Bredenoord personnel.

1. Access doors for

engine and generator

maintenance (only for

Bredenoord personnel)

2. Engine liquids access door

3. Access hatch to control

compartment

4. Feed-through for power

cables and fuel hoses

5. Access door to motor

cooling unit

Description 14

1. Cooling unit cooling air

exhaust vent

2. Engine compartment

cooling air and exhaust

gases vent

3. Access door to battery and

coolant

4. Cooling and engine air

inlet vent

5. Access doors for cooling

maintenance (only for

Bredenoord personnel)

2.2 Main components, engine and generator compartment

WARNING

• Risk of contact with hot parts when entering the generator set. These parts can cause

serious burns. Wear protective gloves when working on the generating set.

• Risk of contact with moving parts when entering the generator set. Only enter the

generator set when the engine has stopped.

• The sound pressure level in this generating set while it is in operation exceeds 85 dB(A).

For this reason, you must wear hearing protection when you open an access door to or

enter the generating set while it is in operation.

Description 15

2.2.1 Engine liquids access door

Engine and generator liquids side

1. Engine block

2. Generator

3. Automatic oil top-up

system oil reservoir


system tap

5. Oil drain pump

6. Battery switch

7. Drip tray float test lever


system three-way tap


system controls

10. Engine oil filler opening

11. Oil dipstick

12. Fuel lines bleed system

13. Drip tray

NOTICE The oil drain pump, drip tray test switch and the automatic oil top-up system

three-way tap may only be operated by Bredenoord personnel. Incorrect operation can

damage the generating set.

Description 16

Engine room ventilation

INFO For convenience, the engine and generator access door is not shown in the

following illustration. This door may only be opened by Bredenoord personnel.

1. Engine room fan

2. Engine room fan isolator

switch

3. Work light

Motor room lighting

1. Work light timer

Description 17

2.2.2 Access door to battery and coolant room

Engine and generator battery side

1. Generator

2. Air filter housing

3. Batteries

4. Engine block

Coolant

1. Coolant reservoir

2. Coolant level indicator

3. Low coolant level

transmitter

4. Coolant filler line stopcock

5. Coolant filler pump

6. Coolant filler hose

Description 18

Engine room ventilation

INFO For convenience, the engine and generator access door is not shown in the

following illustration. This door may only be opened by Bredenoord personnel.

1. Engine room fan

2. Engine room fan isolator

switch

3. Work light

Lighting and emergency stop

1. Work light timer

2. Emergency stop

2.3 Main components, cooling and fuel compartment

WARNING

Description 19

• Risk of contact with moving parts in the cooling and fuel compartment. Do not insert

objects or body parts into the fan grill.

• The sound pressure level in this generating set while it is in operation exceeds 85 dB(A).

For this reason, you must wear hearing protection when you open an access door to or

enter the generating set while it is in operation.

The cooling and fuel compartment contains the following main components:

Engine cooling

1. Cooling unit

2. Cooling fan

Description 20

Fuel

1. Fuel filler opening

2. Connection for tanker

safety level limit sensor

3. Drip tray float test switch

WARNING

• Diesel fuel is flammable. Make sure that there are no ignition sources in the area when

working with diesel fuel. Avoid vapour releases by keep the generating set's filler cap

closed whenever possible.

• Diesel fuel is toxic. Avoid inhaling high concentrations of diesel fumes. Wear protective

gloves when working with diesel fuel.

NOTICE

• Diesel fuel is harmful to the environment. Avoid leaks. Clean up diesel fuel spills

immediately.

• The drip tray float test switch may only be operated by Bredenoord personnel. Incorrect

operation can damage the generating set.

Description 21

Lighting

1. Work light timer

2. Work light

3. Communication cable

used when linking a

number of generating sets.

Description 22

2.4 Main components, control compartment

The access hatch to the control compartment gives access to the main power panel (1 to 4

inclusive, 6, 7 and 9), the external fuel hoses, the control panel and the cooling and heating control

cabinet.

1. Powerlocks distribution

switches (Q2, Q3, Q4)

2. Overcurrent protection,

connecting rail measuring

voltage (F4)

3. Overcurrent protection,

temperature control and

generator measuring

voltage (F2, F2.3, F2.6,

F2.11, F2.12, F2.13)

4. Master switch (Q1)

5. Control panel

6. Auxiliary power supplies

7. Configuration of earthing

system (TN / IT) and

configuration of master

switch (three / four pole)

8. External fuel hoses and

fuel cock

9. Connection points for

power output

2.4.1 Master switch

The master switch (Q1) switches both the three sets of Powerlocks and the consumers connected

via the cable eye bolt connection.

Description 23

INFO The master switch is electrically opened and closed by the controller. The master

switch is not operated by hand during normal operation of the generator.

1. Reset button

2. General status LEDs

3. Message screen

4. Error status LEDs

5. Open master switch knob

6. Close master switch knob

7. Closing spring charging

lever

8. Closing spring charging

indicator

9. Master switch position

indicator

Master switch status

OFF, closingspring discharged

OFF, closing springcharged, switch not ready

OFF, closing springcharged, switch ready

OFF, spring discharged: The generated power is not supplied to the consumers. The closing

spring is discharged.

OFF, spring charged, switch not ready: The generated power is not supplied to the consumers.

The closing spring is charged, but the main switch is not ready for closing because of an error

(error status) or an interlock.

OFF, spring charged, switch ready: The generated power is not supplied to the consumers. The

closing spring is charged and the main switch is ready for closing.

ON, closingspring discharged

ON, closing spring charged

ON, closing spring discharged: The generated power is supplied to the consumers. The closing

spring is discharged.

ON, closing spring charged: The generated power is supplied to the consumers. The closing

spring is charged, but the main switch is not ready for closing because it is already closed.

Description 24

2.4.2 Distribution switches

Due to its high power input, the generating set has three sets of Powerlocks next to each other.

The left distribution switch switches the left set of Powerlocks, the centre distribution switch

switches the central set of Powerlocks and the right distribution switch switches the right set of

Powerlocks.

1. Left distribution switch

(Q2)

2. Centre distribution switch

(Q3)

3. Right distribution switch

(Q4)

The distribution switches have three positions.

OFF ON TRIP

OFF: The generated power is not supplied to the consumers connected to the Powerlocks.

ON: The generated power is supplied to the consumers connected to the Powerlocks.

TRIP: The generated power is not supplied to the consumers connected to the Powerlocks. The

distribution switch has moved to the TRIP position because of an overload (>320 A).

The TRIP position can be reset by setting the switch to the OFF position and then to the ON

position.

Description 25

DANGER

• The cause of the fault must always be corrected before the switch may be reset to the

ON position. Electrocution hazard

• The distribution switches do not switch off the cable eye bolt connection. The master

switch must always be set to the OFF position before carrying out work on the cable eye

bolt connection. Electrocution hazard

2.4.3 Connection points for power output

Consumers can be connected with Powerlock connectors or cable eye bolt connections.

The Powerlock connection points are divided into 3 groups. Each group is equipped with a

distribution switch. Each group carries a maximum of 320 A.

Consumers can also be connected to the copper connection strips with cable eye bolt connections.

The full generator power supply can then be carried to one consumer (maximum 720 A).

2.4.4 Control panel

The control panel has the following controls and options:

1. External control socket

2. Controller

3. Frequency meter and

voltmeter

4. Mode selector switch

(S18)

5. Cooling and heating

control panel

6. Emergency stop

7. Control compartment

lighting

8. CAN-bus sockets

The control compartment lighting button switches the LED strips above the control panel and main

power panel on and off.

CAN-bus cables can be plugged into the CAN-bus sockets to link generators to each other.

All Bredenoord external control modules are equipped with a 24-pin connector for the external

control of the generating set.

Description 26

2.4.4.1 Messages on the display

Information about the generating set shown on the controller display includes:

• Total operating hours

• Generator frequency

• Generator voltage

• Engine oil pressure

• Engine coolant temperature

• Engine speed (RPM)

• Master switch status

• Output power

• Starting battery voltages

• Voltage by phase

• Current intensity by phase

• Load

• Power by phase

• Fuel level

The values are displayed on different pages. The up and down arrow buttons next to the display

pages are used to move through the pages.

Description 27

2.4.4.2 Mode selector switch

The generating set is equipped with a four-position mode selector switch (S18).

0 1 2 3

(OFF) (AUTO) (POWERMANAGEMENT) (HAND)

0 (OFF): The generating set is off.

1 (AUTO): The generating set can be controlled externally. The external controller controls the

starting and stopping of the generating set.

2 (POWERMANAGEMENT): The generating set is controlled by the power management function.

3 (HAND): The generating set can be started and stopped as planned by the user.

CAUTION The generating set can start unexpectedly when the mode selector switch is set

to position 1 (AUTO) and position 2 (POWERMANAGEMENT). Do not enter the generating

set when the switch is set to one of these positions.

Power management (POWERMANAGEMENT)

The power management function can be used when a number of generating sets run in parallel

with the electrical grid or off grid. The power management function determines which generating

sets will need to be started or stopped. This is based on a load evaluation. Power management

ensures that there is sufficient generating power and avoids excess power generation.

INFO The power management function must be configured to the specific situation

before it may be enabled. Do not set the mode selector switch to position 2

(POWERMANAGEMENT) until Bredenoord personnel have configured this functionality.

Description 28

2.4.4.3 Interior

The following switches are located inside the control cabinet.

1. Generator monitoring

bridging switch (S34)

2. 50 Hz - 60 Hz selector

switch (S36)

3. Generator - mains selector

switch (S28)

NOTICE These switches may only be operated by Bredenoord personnel. Risk of damage

to the generator and the consumers connected to the generator.

2.4.5 Overcurrent protection, temperature control and generatormeasuring voltage

1. Overcurrent protection, control panel heating (F2.3)

2. Overcurrent protection, control panel air-conditioning (F2.6)

3. Overcurrent protection, generator measuring voltage (F2)

4. Cooling fan motor protection switch (F2.11)

5. Liquid side engine room fan motor protection switch (F2.12)

6. Battery side engine room extraction fan motor protection switch (F2.13)

Description 29

The control panel heating and air-conditioning are protected with a two pole overcurrent protection

switch.

ON OFF

The generator measuring voltage is protected with a four pole overcurrent protection switch.

ON OFF

The engine room is equipped with two electrically controlled fans. The cooling unit is equipped with

an electrically controlled cooling fan. These fans are equipped with motor protection switches.

ON OFF

NOTICE The controller does not check the status of the cooling fan motor protection

switch. If the cooling fan is off when the engine is running, there is a risk of overheating,

resulting in engine damage.

Description 30

2.4.6 Auxiliary power supplies

1. Power input socket

2. Power output socket

3. Engine heater circuit

breaker (F5)

4. Power output safety switch

(F5.7)

Consumers can be connected to the power output socket using a 32 A CEE plug. This power outlet

can supply both generator and busbar power.

The power input socket receives power for the battery charger and engine heater. The power

supply cable is connected to the socket using a CEE connector. The battery charger keeps the

batteries charged during longer periods of inactivity. The engine heater heats the engine coolant to

ensure that the generating set can be easily started in a low-temperature environment and can be

put under load without a long wait.

The engine heater is rated at 1500 W and draws approximately 6.5 A. The connection cable is not

included as standard.

2.4.7 Master switch with three pole or four pole switching

WARNING Only Bredenoord may make changes to the configuration of the neutral

conductor.

The generating set is equipped with an option for the selection of three pole (3 phases) or four pole

(3 phases + neutral) switching.

The upper strip can be used to bridge the neutral of the four pole master switch. The master switch

then switches as a three pole switch.

Description 31

Three pole master switch Four pole master switch

1. Bridged master switch

neutral contacts

2. Non-bridged master switch

neutral contacts

3. Door

Three pole master switch circuit diagram Four pole master switch circuit diagram

2.4.8 Earthing system (TN / IT)

WARNING Only Bredenoordpersonnel may carry out modifications of the earthing circuit.

CAUTION Generating sets should be earthed in accordance with the TN earthing system

whenever possible. More information about systems and earthing is available in NEN 1010

(Dutch-language standard).

Description 32

The generating set can be connected using the TN system or IT system.

TN system IT system

1. PE-N connection

2. No PE-N connection

3. Door

TN system

The drawing shows that the generator's neutral and earth conductors are connected to the system

earth. An earth rod is driven when no good system earth is available. Do not drive this rod yourself:

a number of measurements need to be carried out to determine the length and position of the

earth rod. Bredenoord can give you information about approved companies specialized in driving

earth rods. The generating set is equipped with an earthing point for the connection to earth.

IT system

The IT system is used sometimes when the generating set cannot be earthed or earthing is less

desirable for mobility reasons. In an IT system the generating set's neutral is not earthed and the

Description 33

neutral and protective cable are separated from each other in the generator. The load's housing is

earthed instead. In addition, an insulation monitoring device is fitted.

This ensures that an insulation fault cannot result in the formation of a circuit via the generator's

neutral. IT systems are often used in the shipping industry, specific hospital zones and industrial

applications with stringent requirements.

2.4.9 Fuel supply

The generating set can be connected to an external fuel tank. The generating set is equipped with

two fuel hoses for this purpose. These are located in the space under the power output connection

points. The black hose is the fuel feed line. The blue hose is the fuel return line.

1. External fuel hoses

2. Fuel selector cock

Description 34

3 Safety

The generating set has been carefully designed and expertly built to operate safely. The EC

declaration (see EC Declaration of Conformity on page 85) confirms this. However, there are

always still hazards and safety risks that cannot be eliminated. The operating functions of the

machine and its operation by the user present these dangers and risks. This section covers safety

instructions and precautions, how you are made aware of them and the requirements that must be

met by the user. It is very important that you are thoroughly familiar with the safety instructions and

regulations and observe them under all circumstances!

WARNING Ignoring or failing to follow the safety instructions may result in serious injury.

3.1 General safety instructions

WARNING

• Everyone responsible for operating the generating set must at least fully read and

understand sections Safety on page 35 and Operation on page 62.

• Do not use the generating set if your concentration is impaired, due to fatigue or alcohol

consumption for example.

• Implement internal procedures and supervision to ensure that all power supplies are

shut off.

• The generating set may not be operated during cleaning, inspection, repair or

maintenance and must be disconnected from the power supply by switching off at the

master switch.

• Before work can be carried out on this machine, the machine must always be switched

to the safe state.

• The existing protection provisions must not be removed.

• Diesel fuel is flammable. Make sure that there are no naked flames or ignition sources

in the area when working with diesel fuel. Avoid vapour releases by keep the generating

set's filler cap closed whenever possible.



• Take personal and general safety measures when carrying out maintenance or other

work.

• Some batteries contain corrosive acid. Wear protective gloves when working with

batteries.

Safety 35

CAUTION

• The generating set can start automatically by being switched on remotely or by

command from the energy management function.

• The renter of the generating set is responsible for ensuring that all persons work in

accordance with the instructions in this manual.

• In the event of malfunctions, contact Bredenoord.

NOTICE

• Pressure washing is not permitted. This can cause damage to the electronics and other

parts.

• The liquids used in this generating set, such as diesel fuel, lubricant and coolants, are

harmful to the environment. Avoid leaks. Dispose of surplus liquids in accordance with

the local legislation and regulations.

3.1.1 Mechanical hazards

The generating set contains various moving parts. These parts are shielded by doors or an

additional housing. However, in exceptional cases it is still possible to come into contact with

moving parts.

WARNING Never put a hand or finger through the protective guards.

CAUTION The generating set's access doors and hatches other than the control

compartment access hatch may not be opened while the generating set is in operation.

3.1.2 Electrical hazards

WARNING

Electrocution hazard

• Work on the electrical installation may only be carried out by an appropriately authorized

person.

• All the electrical connections must be connected properly.

• Always assume that the generating set is live until you have switched off the power

yourself.

• There is a danger that power may be present in the generating set even after the power

is switched off, due to power being fed back from another power source. Therefore,

always check whether the system is completely de-energized.

• Connectors may only be disconnected if the electrical circuit is de-energized.

• Beware of live parts in the switchboard cabinets and do not touch them.

• Always work in accordance with the applicable national legislation and regulations.

Safety 36

• Avoid contact with damaged electrical parts.

• Short-circuited batteries can cause very high currents to flow.

NOTICE Prevent diesel oil, lubricants and battery acid from coming in contact with

electrical cables.

3.1.3 Hot surfaces

WARNING Some parts of the generating set, such as the turbocharger or exhaust, can

reach high temperatures that can cause severe burns on coming into contact with them.

For this reason, always wear protective gloves when working on the generating set.

3.1.4 Sound pressure level

WARNING The sound pressure level in this generating set while it is in operation exceeds

85 dB(A). For this reason, you must wear hearing protection when you open an access

door to or enter the generating set while it is in operation.

It is recommended that you wear hearing protection when using a machine producing a sound

pressure level that exceeds 70 dB(A). Hearing protection must be worn when the sound pressure

level exceeds 85 dB(A).

The sound pressure level is measured at the workplace under normal working conditions and in

accordance with European Machinery Directive 2006/42/EC. The measurement was carried out at

a distance of 1 metre from the machine and at a height of 1.60 metres above the work floor. The

value of the measured sound pressure level depends on various parameters.

3.1.5 Vibration

During normal use this unit complies with the anti-vibration requirements prescribed in European

Machinery Directive 2006/42/EC.

3.1.6 Working environment

CAUTION

• Prevent unauthorized persons from gaining access to the generating set.

• Keep the surfaces of the generating set clean.

• Remove spilled diesel oil or lubricants in, on or next to the unit immediately.

• Make sure that no tools or other objects remain in the generating set after work.

3.1.7 Maintenance

CAUTION Failure to carry out repairs or maintenance work in good time can cause

personal injury or damage to the generating set.

Safety 37

NOTICE

• Do not postpone maintenance or repair work.

• Have worn parts replaced immediately by Bredenoord.

• Only use spare parts listed in the Bredenoord specifications for repair or replacement.

3.2 Warnings during use

WARNING

• Before putting the generating set into operation, make sure that no work is being carried

out on the generating set and that it is ready for operation.

• Only start the generating set when all safety measures have been observed.

• Only operate the generating set if the emergency stop is visible and accessible.

• Do not operate the generating set near flammable gases.

• The operating personnel must be familiar with all situations, so that quick and effective

action can be taken in the event of an emergency.

CAUTION

• Unauthorized persons may not operate the generating set. This must be checked by the

user(s).

• Only start the generating set when all access doors are shut.

• If any changes occur, such as poorly functioning parts, unusual vibration or strange

noise, contact the manufacturer immediately.

• Only authorized persons may work with or on the generating set.

• Personnel may only perform work for which they have been trained. This applies to

maintenance work and normal use.

• If an operating employee notices faults or risks or disagrees with safety measures, he

must report this to his supervisor. His supervisor can contact Bredenoord if necessary.

• Everyone must follow the safety instructions; otherwise they can be a danger to

themselves and to others. Always strictly follow the work instructions.

3.3 Personal protective equipment

Personal protective equipment must be used as required by local laws and regulations.

WARNING

• Wear suitable fall protection when working on the generating set.

• Wear hearing protection at noise levels > 85 dB(A).

• Wear protective gloves when working on the generating set.

Safety 38

3.4 Standard safety features

WARNING The existing protection provisions must not be removed.

The generating set is equipped with a number of facilities that enable safe operation. The

generating set is equipped with doors that can be locked with a key. The doors have a mechanism

which opens the door from the inside to make sure that no one can get locked in. All moving parts

in the generating set are fitted with extra guards. Pictograms have been applied to the inside and

outside to alert the operator to the residual risks.

3.4.1 Emergency stop system

NOTICE Only use the emergency stop in an emergency. In situations other than

emergencies, always work through the full shutdown procedure to stop the generating set.

Use of the emergency stop can damage the generating set.

The generating set is equipped with an emergency stop system with two emergency stop buttons.

One emergency stop is located inside the generating set next to the access door to the batteries.

The second emergency stop button is mounted on the control panel and is accessible through a

cut-out in the access hatch to the control compartment.

Safety 39

Pressing the emergency stop button stops the generating set immediately and sets the master

switch to the OFF position. This breaks the connection to the plant or consumers connected to the

generating set.

WARNING The emergency stop button is covered with a metal plate during transport.

After installation, the metal plate must be pushed aside immediately so that the emergency

stop is accessible for operation.

Resetting an emergency stop

CAUTION The generating set may start automatically on resetting the emergency stop.

1. Make sure that the emergency has been resolved and that the emergency stop may be reset.

2. Turn the emergency stop button to the left. The button will spring out.

3. Press the controller's Alarmlist button. A list of alarm messages will be displayed.

4. Press the controller's Reset error (exclamation mark with cross) button. The alarm message

will disappear from the display.

The generating set can start automatically when its mode selector switch (S18) is set to position 1

(AUTO) or 2 (POWERMANAGEMENT). The generating set will need to be started manually when

the mode selector switch is in position 3 (HAND).

Safety 40

3.4.2 Battery switch

The generating set is equipped with a battery switch. This switch can be used to disable the

batteries so that the generating set cannot be started unintentionally.

The battery switch is located behind the engine liquids access door.

1. Battery switch

The battery switch has two positions:

OFF (vertical) ON (horizontal)

OFF: The batteries are disconnected.

ON: The batteries are connected.

3.4.3 Pictograms on the machine

CAUTION

• Check all instructions and hazard symbols on the machine.

• Make sure that all safety instructions on the machine remain clean and legible.

• Keep the pictograms clean and legible. Replace damaged pictograms immediately or

report this to Bredenoord.

Safety 41

The following instructions and pictograms are applied to the generating set:

Label Location Description

On the inside of the motor

liquids access door.

Attention, read the manual

beforehand.

Brief instructions for starting

the generating set.

Brief instructions for stopping

the generating set.

On the control panel next to the

emergency stop button.

Be alert to hazards when

performing work.

Read the manual beforehand.

On the fuel filler cap. Indicates the fuel type.

On and on the back of the

black door giving access to the

main power connection strips.

Warns of incorrect connection.

Around the emergency stop

buttons.

Indicates the function.

On the guards over the fans. Fan behind the guard.

Near hot parts. Danger of contact with hot

parts.

On the control panel. Warning that the generating set

can start automatically.

Safety 42


At the filler cap of the radiator. Danger: vessel under pressure.

On covers. Danger of high voltage.

On the drive belt shields. Danger of rotating parts.

On the engine and generator

maintenance access doors.• Flammable.

• Hazardous to the

environment.

On the access hatch to the

control compartment.

Conforms to NEN 3140 and

BGV A3.

On the engine liquids access

door and on the batteries

access door.

States maximum sound

pressure level.

On the engine liquids access

door and on the batteries

access door.

Hearing protection must be

worn.

Safety 43


On the access hatch to the

control compartment.

Regulations for the safe use of

Bredenoord generating sets.

3.5 Safe state

WARNING Always set the generating set in the safe state before carrying out any checks

or work on the set. A generating set that is not in the safe state can start automatically. This

can give cause to entrapment, electrocution or hearing injury risks.

Setting the generating set in the safe state disables the batteries so that the generating set cannot

be started unintentionally.

1. Battery switch

1. Open the engine liquids access door.

2. Turn the battery switch anticlockwise: OFF (vertical position).

Safety 44

4 Placement

The generating set can be easily placed with a crane or forklift.

1. Cooling unit cooling air

exhaust vent

2. Engine compartment

cooling air and exhaust

gases vent

3. Container lifting points

4. Cooling and engine air

inlet vent

WARNING Use only approved container lifting equipment to lift the generator set and take

account of the gross weight.

Place the generating set on a level, firm surface and take account of the gross weight of the

generating set (including fuel).

Position the generating set so the doors can be fully opened on all sides. This space is necessary

so the unit has adequate cooling and the service technician can perform his tasks.

Do not place the generating set under obstacles, such as a canopy or tree branches. The exhaust

gases are discharged at the top of the unit and can be very hot.

WARNING The emergency stop button is covered with a metal plate during transport.

After installation, the metal plate must be pushed aside immediately so that the emergency

stop is accessible for operation.

Placement 45

4.1 Opening access door

1. Open the metal flap.

2. Unlock the lock with the key.

3. Push the metal lip marked "PUSH" inwards.

4. Pull the black plastic handle forwards.

5. Open the door.

Placement 46

5 Installation

WARNING

• Always set the generating set in the safe state before carrying out any checks or work

on the set. If the generating set is not in the safe state, it can start automatically. This

can give cause to entrapment, electrocution or hearing injury risks

• Check whether the main power cables are live. Power can be fed back from an external

source. Electrocution hazard

CAUTION Only authorized persons may make the electrical connections to the generating

set (comply with legal regulations).

5.1 Connecting main power cables

NOTICE The generating set has a right-hand rotating field.

The main power cables can be connected by means of a plug connection or a cable eye bolt

connection.

Plug connection Cable eye bolt connection

5.1.1 Connecting plug connector

The plugs (Powerlocks) are coded. The coding and shape of the plugs match to the corresponding

connection points in the generating set. Incorrect connection is therefore impossible.

Installation 47

1. Lower strain relief brackets

2. Plug connections

1. Open the access hatch to the control compartment.

2. Remove the black protective cap from the socket.

3. Fit the plug into the corresponding socket and tighten the coupling (clockwise) until the locking

pin falls into its notch.

4. Repeat the preceding steps for the other plugs.

5. Secure the cables to the lower strain relief bracket using suitable cable ties.

Cable ties are not supplied as standard with the generating set.

6. Route the cables to the outside and close the access hatch to the control compartment.

Installation 48

WARNING Make sure the cables are not pinched by the hatch. Risk of electrocution

when the cable is damaged.

5.1.2 Connecting cable eye bolt connection

The main power cables are connected to the main power connection strips by means of cable eye

bolt connections. The strips are located behind the black plastic door. The door is locked with the

supplied key.

The correct connection method for each phase is indicated by codes on the main power connection

strips.

1. Door

2. Connection points

3. Upper strain relief bracket


2. Open the black plastic door (1).

3. Remove the bolt, nut and two washers from the main power connection strip.

4. Fasten the cable eye of the cable to the main power connection strip using the bolt, nut and

two washers.

Installation 49

NOTICE Make sure the cables are connected correctly.

5. Repeat the above steps for the other cables.

6. Secure the cables to the strain relief bracket using suitable cable ties.

Cable ties are not supplied as standard with the generating set.

7. Close the black plastic door (1).

8. Route the cables to the outside and close the access hatch to the control compartment.



Installation 50

5.2 Connecting external controller

The external controller of the generating set can be connected via a 24-pin connector or via a

terminal strip X10, to terminals 11 and 14. All external control modules from Bredenoord are

equipped with a 24-pin connector.

INFO

• A cable for the external control is not supplied as standard with the generating set.

• A list of the connection points on the terminal strip is enclosed on Connection stripcontact points on page 82

1. 24-pin connector

2. Terminal strip X10

Installation 51

5.3 Connecting a number of generating sets

A number of generating sets can run in parallel with the electrical grid or off grid. The generating

sets communicate via a Controller Area Network (CAN-bus).

1. CAN-bus socket

Connect generating sets running in parallel to each other with a CAN-bus cable. Remove the

protective cap and connect the cable to one of the two sockets. Connect the other end of the cable

to a following generating set.

INFO The CAN-bus cable is located in the cooling and fuel compartment.

5.4 Connecting earthing

DANGER Risk of electrocution when earthing is missing or faulty.

The metal parts of the generating set that are exposed to contact with persons may be live due to

inadequate insulation or other damage. The generating set must be fitted with a proper earthing

system to protect persons and consumers connected to the set.

The generating set is equipped with an earthing connection strip. The consumer must connect

the generating set to the earthing system of an existing plant or a suitable earthing rod. The

connection must be made using an insulated copper conductor with a minimum cross-sectional

area of 16 mm² or a bare copper conductor with a minimum cross-sectional area of 25 mm².

The earthing cable is connected to the earthing connection strip by means of a cable eye bolt

connection.

Installation 52

The earthing connection strip is located behind the black plastic door. The door is locked with the

supplied key. The earthing connection strip can also be accessed without needing to open the

black plastic door.

1. Earthing connection strip

2. Lower strain relief bracket


2. Attach the cable eye of the cable using the screw on the connection point (1) on the earthing

connection strip.

3. Secure the cable to the lower strain relief bracket using a suitable cable tie (2).

INFO Cable ties are not supplied as standard with the generating set.

4. Route the cable to the outside and close the access hatch to the control compartment.

WARNING Make sure the cable does not get pinched in the door.

5.5 Connecting the fuel tank

WARNING

• Diesel fuel is flammable. Make sure that there are no ignition sources in the area when

working with diesel fuel. Avoid vapour releases by keep the generating set's filler cap

closed whenever possible.



NOTICE


immediately.



Installation 53

1. External fuel hoses

2. Fuel selector cock


2. Remove the fuel hoses from the compartment.

3. Remove the sealing caps from the hoses.

4. Connect the hoses (1) to the external fuel tank.

Black is the fuel feed line. Blue is the return line.

5. Turn the fuel selector cock (2) to the "External” position (raised).

6. Route the hoses to the outside and close the access hatch to the control compartment.

NOTICE Make sure the hoses are not pinched by the hatch. Pinching could cause

damage to the hoses, could block the fuel supply and could cause leaks.

NOTICE After disconnecting the external tank, fit the sealing caps on the hoses. This

prevents contamination and fuel leakage.

5.6 Bleeding the fuel lines

NOTICE


immediately.



The fuel system must be bled after connecting the external fuel tank. The generating set is

equipped with a hand-operated bleeding pump for this purpose. The generating set may not be

started until the fuel system has been bled.

Installation 54

NOTICE Air may enter the engine's fuel system if the fuel lines are not fully bled. Air in the

engine's fuel system will stop the engine and then, in addition to bleeding the fuel lines,

it will also be necessary to bleed the fuel pump, fuel filter and injection pump. Contact

Bredenoord as the situation arises.

1. Bleed nipple in feed line

2. Bleed nipple in return line

3. Hand pump

4. Fuel filter with water

separator

5. Bleed hose with quick-

release coupling

1. Open the engine liquids access door.

2. Remove the bleeding hose with quick coupling. This is hooked next to the hand pump.

3. Connect the bleed hose with quick coupling to the bleed nipple in the feed line (1).

4. Hang the bleed hose in a leakproof drip tray.

5. Work the hand pump (3) by pressing and releasing it several times. Work the pump until no

more air comes out of the bleed hose.

6. Remove the bleed hose by pulling the ring of the quick-release coupling.

7. Connect the bleed hose with quick coupling to the bleed nipple in the return line (2).

8. Hang the bleed hose in a leakproof drip tray.

9. Work the pump by pressing and releasing it several times. Work the pump until no more air

comes out of the bleed hose.

10. Remove the bleed hose by pulling the ring of the quick-release coupling.

11. Hang the bleed hose with quick coupling back on its hook.

Installation 55

12. Close the engine liquids access door.

NOTICE Dispose of the surplus diesel fuel in accordance with the local legislation and

regulations.

5.7 Connecting the engine heater

The generator is equipped with an engine heater and battery charger. These ensure that the

generator set can still be started at low ambient temperatures and after a longer period of in which

the set has not been used. The generating set will need to be connected to an external power

supply for the engine heater and battery charger to work.

INFO A connection cable for the engine heater/battery charger is not supplied as standard

with the generating set.


2. Pick up the connection cable for the engine heater/battery charger.

3. Open the plug cover.

4. Plug a CEE connector into the power input socket.

5. Route the cable to the outside and close the access hatch to the control compartment.



6. Plug the plug on the other end of the connection cable into a socket.

Installation 56

6 Starting up

A number of checks must always be carried out before starting the generator set.

WARNING Always set the generating set in the safe state before carrying out any checks

or work on the set. A generating set that is not in the safe state can start automatically. This

can give cause to entrapment, electrocution or hearing injury risks.

NOTICE Always carry out these checks. Failure to do so can cause serious damage to the

generating set.

Check:

1. The level of the engine oil.

2. The level of the coolant.

3. The fuel level.

4. The position of the fuel cock.

5. The position of the protection switch for the cooling fan.

6.1 Checking oil level

NOTICE An oil level that is too low or too high can cause serious damage to the engine.

Therefore, check the oil level regularly.

To prevent damage to the engine, check the engine oil level every day.

1. Dipstick

2. Oil filler cap

The oil level can be checked manually using the dipstick.

Starting up 57

1. Remove the dipstick (1) from the engine block.

2. Check the oil level on the dipstick.

• No action is needed when the oil level is between the Min and Max marks. Continue from

Checking automatic oil top-up system on page 58.

• The oil will need to be topped up when the oil level is too low. Continue from Top up the oilon page 72.

• Oil will need to be drained when the oil level is too high. This may only be done by an

authorized person.

3. Put the dipstick back into the engine block.

6.2 Checking automatic oil top-up system

The risk of the engine oil level becoming too low during long generating set operating periods must

be avoided. The generating set is equipped with an automatic oil top-up system to avoid irreparable

damage to the engine. This system automatically maintains the correct oil level in the engine.

1. Oil filler cap

2. Sight glass

3. Oil cock

Check the following each time the generating set is started and after every 24 hours of operation:

1. Check that the oil filler cap (1) on the oil top-up tank is tight.

2. Check the oil level on the sight glass (2) mounted on the side of the oil top-up tank.

Starting up 58

NOTICE

• An oil level that is too low can cause serious damage to the engine. If the oil tank is

empty, contact Bredenoord immediately and do not start the generating set.

• A rapid drop of the oil level in the top-up tank can indicate high oil consumption. To

prevent damage to the engine, contact Bredenoord as soon as possible.

3. Check that the oil cock (3) is open (in line with the oil lines).

6.3 Checking coolant level

The coolant level indicator is located behind the battery access door.

Check the coolant level in the sight glass. The blue line is the minimum level. The red line is the

maximum level.

If the coolant level is below the minimum level then there is probably a leak in the cooling circuit.

Resolve the cause of the loss of coolant level before topping up the coolant. Contact Bredenoord

about this.

NOTICE Coolant may only be added by appropriately authorized persons.

6.4 Safety switch for cooling fan

The cooling unit is equipped with an electrically controlled cooling fan. This fan is fitted with a

safety switch.

Check that this switch is in the correct position (ON).

NOTICE If the cooling fan is off when the engine is running, there is a risk of overheating,

resulting in engine damage.

Starting up 59

6.5 Checking fuel cock position

There is a fuel cock in the generating set. This fuel cock can be used to select whether the fuel

supply comes from the internal fuel tank or an optional external fuel tank.

Fuel supply fromthe internal tank

Fuel supply froman external tank

The fuel cock must be set to the correct position for the tank that is in use.

• Handle raised: fuel supply from the internal tank

• Handle lowered: fuel supply an external tank

NOTICE The position of the fuel cock must not be changed during operation.

Starting up 60

6.6 Checking fuel level

INFO A running engine can be damaged if it runs out of fuel.

Make sure that the fuel tank is not run empty. When a fuel tank has been run empty then the entire

fuel system must be bled after refuelling before starting the engine.

Internal tank

The fuel level is shown on the generating set's controller.

1. Fuel level display

Read the fuel level. Top up the fuel if necessary.

NOTICE Always top up the fuel when a level alarm is displayed. The alarm percentage can

vary as determined by the controller settings.

External tank

Check the fuel level in the external fuel tank. Top up with fuel if necessary.

Starting up 61

7 Operation

Once all the necessary checks have been carried out and found to be OK, the generating set may

be operated.

The generating set must be started before it can generate power and supply current to consumers.

Starting and stopping can be performed manually or automatically.

Manually: The generating set is started and stopped as planned by the user.

Automatically: The generating set can be controlled automatically. The automatic

control system starts and stops the generating set. The generating set's

controls provide for a sufficient post-running period for each stop.

External or internal commands are sent to start and stop the generating

set. This command can be sent, for example, from an:

• External timer

• External light-sensitive switch

• External backup power controller

• External or internal float switch

• Internal energy management function

The master switch must also be set to the appropriate position to supply power to the users.

7.1 Manual operation

7.1.1 Starting

WARNING Before starting the generating set make sure that no work is being carried out

on the electrical plant connected to the generating set.

CAUTION If the generating set is operating unattended, all the doors must be locked. Use

the supplied key.

INFO

• The battery switch must be set to ON (horizontal).

• The work light in the generating set housing may light when the battery light is switched

to on.

The manual operating mode (MANUAL) is used to start and stop the generating set as planned by

the user.

Operation 62

1. Open/Close GCB button

INFO The function of the button is dependent on the state of the generating set.

• When the master switch (GCB) is open, the button will display the Close GCB function.

• When the master switch (GCB) is closed, the button will display the Open GCB function.


2. Check the position of the master switch (Q1) and distribution switches (Q2, Q3, Q4). They

must be in the OFF position.

3. Set the mode selector switch (S18) to position 3 (HAND).

The controller display switches on.

4. Press the Start button on the controller.

The generating set starts up.

5. Wait until the generator symbol (round symbol with "G") on the display turns green.

6. Press the button for Close GCB (1).

The consumer symbol (factory icon) turns green.

The master switch (Q1) automatically moves to the ON position.

7. If the power consumer is connected to a set of Powerlocks then switch the corresponding

distribution switch (Q2, Q3, Q4) to the ON position.

The generating set is now ready for operation.

INFO Keep the control compartment access hatch closed whenever possible.

7.1.2 Stopping

1. Open/Close GCB button

Operation 63

INFO The function of the button is dependent on the state of the generating set.

• When the master power switch (GCB) is open, the button will display the Close GCBfunction.

• When the master power switch (GCB) is closed, the button will display the Open GCBfunction.

1. Switch off all power consumers.

NOTICE Stopping while under load can cause damage to the generating set.



distribution switch (Q2, Q3, Q4) to the OFF position.

4. Press the Open GCB button.

The consumer symbol (factory icon) turns grey.

The master power switch (Q1) automatically moves to the OFF position.

5. Press the Stop button on the controller.

The engine continues to run for a few minutes to allow certain parts to cool down. The post-

run time is shown on the display.

6. The engine can be stopped during the post-running period by pressing the Stop button again.

NOTICE Too short a post-running period can result in overheating and engine

damage.

7. Set the mode selector switch (S18) to the 0 position (OFF).

The generating set is now stopped.

INFO When the generating set will not be used for a longer period of time it is

recommended that the battery switch be set to OFF (vertical).

7.2 Automatic operation

7.2.1 Starting

WARNING Before setting the generating set to ready make sure that no work is being

carried out on the electrical plant connected to the generating set.

Operation 64

CAUTION

• The generating set can start automatically.

• If the generating set is operating unattended, all the doors must be locked. Use the

supplied key.

INFO

• The battery switch must be set to ON (horizontal).

• The work light in the generating set housing may light when the battery light is switched

to on.

The AUTO and POWERMANAGEMENT operating modes are intended for the automated

operation of the generating set, which will then automatically start and stop.


2. Check the position of the master switch (Q1) and distribution switches (Q2, Q3, Q4). These

must be in the OFF position.


distribution switch (Q2, Q3, Q4) to the ON position.

4. Set the mode selector switch (S18) to position 1 (AUTO) or 2 (POWERMANAGEMENT).

The controller display remains off until a start signal is received from an external controller

(automatically) or the power management function switches the generator set on.

The generating set is now ready for automatic starting and stopping.

Operation 65

7.2.2 Stopping

Work through the following steps to stop the generating unit or to make sure that it does not start

automatically.

1. Switch off all power consumers.

NOTICE Stopping while under load can cause damage to the generating set.

When the generating set is switched from the AUTO position, there are two possible

situations:

• The engine of the generating set is not running. No further external control signal will

be transmitted and the power management function has not started the generating set.

Continue from step6 on page 66

• The engine of the generating set is running. An external control signal is transmitted, the

power management function is keeping the generating set running or the engine is still

running down. Continue with the next step.

2. Make sure that no further external control signal can be transmitted to the generating set.



distribution switch (Q2, Q3, Q4) to the OFF position.

5. Wait until the engine has stopped completely and the controller display goes out.

NOTICE The engine may continue to run for a few minutes to allow certain parts

to cool down. Too short a post-running period can result in overheating and engine

damage.

6. Set the mode selector switch to the 0 position (OFF).

The generating set is switched off can no longer be controlled externally.

INFO When the generating set will not be used for a longer period of time then it is

recommended that the battery switch is set to OFF (vertical position).

Operation 66

8 Putting out of operation

WARNING






CAUTION Only authorized persons may make the electrical connections to the generating

set (comply with legal regulations).

8.1 Disconnecting main power cables

After completion of the work, the generating set must be electrically disconnected.

The main power cables can be connected by means of a plug connection or a cable eye bolt

connection.

Plug connection Cable eye bolt connection

Putting out of operation 67

8.1.1 Disconnecting plug connector


2. Strain reliefs

The following procedure describes how the plugs (Powerlocks) must be removed.


2. Remove the strain reliefs that retain the cables.

Do not leave used strain reliefs in the generating set or on the ground.

3. Press the pin of the plug down using a Powerlock Release Key, screwdriver or other suitable

object and then turn the plug anticlockwise and pull it downwards.

4. Repeat the preceding steps for all the plugs.

5. Place the protective caps over the sockets.

6. Close the access hatch to the control compartment.


8.1.2 Disconnecting cable eye bolt connection


2. Strain reliefs

3. Door

The following procedure describes how to disconnect the cable eye bolt connection.


2. Open the black plastic door.

3. Remove the strain reliefs that retain the cables.

Do not leave used strain reliefs in the generating set or on the ground.

4. Dissemble the cable eye bolt connection and remove the cable.

5. Fit the bolt, nut and washers back in the terminal strip.

6. Repeat the preceding steps for the other cables.

7. Close the black plastic door.



8.2 Disconnecting external control

The external control of the generating set is connected via a 24-pin connector or via a terminal

strip X10, to terminals 11 and 14.

1. 24-pin connector

2. Terminal strip X10

8.3 Disconnecting the engine heater

After completion of the work, the engine heater for the generating set must be disconnected.

The following procedure describes how to disconnect the engine heater.

1. Unplug the connection cable for the engine heater/battery charger from the socket.


3. Remove the plug of the connection cable from the motor heater/battery charger socket.

4. Remove the connecting cable.



9 Maintenance and service

Maintenance of the generating set can be divided into maintenance work that must be carried out

daily and work that must be carried out during scheduled service.

The operator of the generating set is responsible for performing the daily checks. The scheduled

service is performed by Bredenoord .

INFO In the event of malfunctions, contact Bredenoord immediately.

9.1 Scheduled service

Scheduled service may only be carried out by Bredenoord personnel and must be carried out

between every 500 to 700 operating hours, or every other year. The operation hours are shown on

the generating set's display.

The Bredenoord service technician signs off his work on the maintenance record plate. This is

mounted on the cooling and heating control cabinet in the control compartment (see Maintenancerecord plate on page 84). This plate shows when (operating hours and/or date) the next service

must be performed.

NOTICE

• When it is time for the next scheduled service, contact Bredenoord immediately.

• Do not clean the generating set with a pressure washer.

9.2 Daily maintenance

The daily maintenance tasks are specified in the following table.

WARNING






Maintenance and service 71

Action When

Check the oil level in the top-up

tank• Before starting.

• After every 8 to 9 operating hours.

Oil level in the engine • Before starting.

• After every 8 to 9 operating hours.

Check coolant level • Before starting the generating set.

9.3 Top up the oil

NOTICE

• An oil level that is too low or too high can cause serious damage to the engine.

• Only top up with oil with the correct specifications: see Technical data on page 12 for

more information.

• Clean up spilled oil immediately.

The engine oil will need to be topped up when the level is too low.

1. Dipstick

2. Oil filler cap

1. Unscrew the oil filler cap (2).

2. Top up oil to the correct level.

NOTICE Regularly check the oil level with the dipstick (1) while topping up with oil to

avoid filling with too much oil.

3. Screw the oil filler cap (2) in place.


9.4 Topping up coolant

WARNING Risk of serious burns.

• The cooling system is under pressure.

• The cooling system is filled with hot coolant.

Do not top up with coolant until the cooling system has cooled down enough. Wear

protective gloves when working with coolant.

NOTICE

• Resolve the cause of the low coolant level (often a leak) before topping up the coolant.

• The coolant may only be topped up by persons authorized to do so.

Do not start the generator when the coolant level is too low and needs to be topped up.

1. Coolant reservoir

2. Coolant level indicator

3. Low coolant level

transmitter

4. Coolant filler line stopcock

5. Coolant filler pump

6. Coolant filler hose

1. Put the coolant filler hose (6) into a storage tank containing sufficient coolant.

2. Open the coolant filler line stopcock (4).

WARNING When the cooling circuit is under pressure then (hot) coolant will flow back

into the storage tank.

3. Work the coolant filler pump (5).

Coolant will flow from the storage tank into the coolant reservoir (1). The coolant level indicator

(2) will show that the level is rising.

4. Stop working the coolant filler pump once the coolant level indicator level has risen to between

the blue and red lines.


5. Close the coolant filler line stopcock.

6. Remove the coolant filler hose from the storage tank.


10 Troubleshooting

There are a number of faults that are simple for the operator of the generating set to solve himself.

This chapter contains a table with the most common faults and the corresponding causes and

solutions. If the unit still does not work after that, contact Bredenoord.

10.1 Alarm status on controller

A new alarm is displayed in the alarm list. A flashing red dot and exclamation mark appear at the

top of the display and an exclamation mark also appears above the "Alarmlist” button.

When the main screen is displayed at the time that the alarm occurs then this screen automatically

switches to the alarm list screen. When another screen is displayed then the alarm list must be

opened by hand by pressing the "Alarmlist” button.

On the occurrence of an alarm, press button to confirm all alarms. The exclamation mark

on the display stops flashing and the red dot goes out. The alarm disappears from the screen only

once the underlying cause has been resolved.

Troubleshooting 75

When the underlying cause has been resolved before the alarm has been confirmed then the

alarm will be displayed as an inactive alarm until it is confirmed.

Example of alarm on display Alarm Solution

• Constant: confirmed alarm. • Resolve the alarm or

contact Bredenoord.

• Constant: confirmed alarm. • Resolve the alarm or

contact Bredenoord.

• Flashing: new active alarm

(not yet acknowledged).

• Press the "AlarmList" to

display the list of alarms.

• Active alarm (not

confirmed).

•Press the button to

confirm all alarms.

• Active alarm (confirmed). • Resolve the underlying

cause of the alarm.

• Inactive alarm (not

confirmed).

•Press the button to

remove all inactive alarms

from the list.

The alarm message can be preceded by an asterisk (*). The alarm message can have one of

several background colours.

• An asterisk before the alarm message indicates that the alarm has yet to be confirmed.

• The background colour indicates the seriousness of the alarm:

• red: high priority

• yellow: regular priority

• grey: low priority

• black: inactive (underlying cause has already been resolved)

Troubleshooting 76

10.2 Master switch error status

The following actions take place in the event of a master switch error:

• The master switch moves to the OFF position

• The reset button pops out

• The Ready LED flashes green

• The message screen on the master switch changes to red and displays the "Press OK to view

detail” message

• One of the error status LEDs lights red

• The error status is transmitted to the generating set's controller and the controller may then,

depending on the nature of the error, also display a message.

The error status LEDs indicate the following errors.

Load pre-alarm (generator does not cut out). The load is between 90 %

and 105 % of the set maximum.

Load alarm (generator does not cut out). The load is higher than 105 %

of the set maximum.

The generator has cut out after longer overloading.

The generator has cut out because of a short circuit or a short peak

overload.

Generator has cut out because:

• The emergency stop button has been pressed

• Power has been supplied to the power output connections

Error during master switch self test. The Ready LED goes out and the

red LED next to the open ended spanner lights. Contact Bredenoord for

the rectification of this fault.

DANGER The cause of the fault must be resolved before the switch can be reset to the

ON position. Electrocution hazard

Troubleshooting 77

10.3 Troubleshooting

The most common problems and their solutions are described in the table below. Please contact

Bredenoord in the event of faults that cannot be resolved using this table.

Fault Cause Solution

Engine does not start. • Liquid drip tray is full

(‘Driptray’ message on control

unit).

• Empty drip tray.

CAUTION Liquids in the drip tray can be harmful to health

and the environment. Always wear protective gloves when

emptying the drip tray. Clean up spilled liquids immediately.

• Battery clamps are loose or

oxidized.

• Tighten or clean battery

clamps.

• Batteries are discharged. • Recharge or replace batteries.

Engine does not start(clicks).

• Defective starter motor or

starter relay.

• Repair or replace starter

motor or starter relay.

• No fuel. • Refill fuel.

• Fuel cock in the wrong

position.

• Set the fuel cock to the correct

position.

• Fuel filters clogged. • Have fuel filters replaced.

Engine cranks normally,but does not start.

• Air in fuel system. • Bleed the fuel system.

• V-belt broken. • Have V-belt replaced.Battery charging error.

• Dynamo defective or carbon

brushes worn out.

• Have dynamo or carbon

brushes replaced.

• Too little engine oil. • Top up engine oil.Oil pressure too low.

• Oil pressure switch defective. • Have oil pressure switch

replaced.

• Water pump or fan belt is too

loose.

• Check belt tension visually.Engine temperature toohigh.

• Radiator clogged. • Have radiator cleaned.

Troubleshooting 78


• Air filter clogged • Replace air filter or clean air

inlet system.

• Coolant level too low. • Top up coolant.

• Fan switch is in the OFF

position (message ‘Wrn

Coolfan RPM’ on the

controller).

• Set the fan switch in the ON

position.

• Too little coolant. • Top up coolant.Coolant level too low.

• Level switch defective. • Have level switch replaced.

• No fuel. • Refill fuel.

• Fuel filters fouled. • Have fuel filters replaced.

• Air in fuel system. • Have lines, connections, fuel

pump, filters and injection

pump bled.

Engine stops.

• Engine overloaded. • Reduce the load.

• Air filter clogged or worn out. • Check air filter and replace if

necessary.

Engine smokingexcessively (black ordark-grey smoke).

• Atomizers defective. • Have atomizers checked.

• Problem with fuel system. • See under "Engine stops".Frequency error orincorrect frequencydisplayed on meter. • Load too high. • Reduce the load.

• Circuit breaker off or fuse

defective.

• Check the corresponding

fuses and circuit breakers.

Engine is running, butvoltmeter does notdisplay correct voltage.

• The wiring is loose. • Check the wiring.

• Master switch is set to off. • Set master switch to the ON

position.

Generator voltage, butthe load is not suppliedwith power.

• Distribution switch is set to off. • Set distribution switch to the

ON position.

Troubleshooting 79


• A circuit breaker is open or

fuse is defective.

• Use the circuit diagrams to

check the power supply to the

module.

• Wiring is loose. • Check wiring.

Machine is on but displayis not lit.

• No battery voltage. • Check batteries and battery

switch.

Troubleshooting 80

Annexes

INFO The annexes only contain the information of importance to the operator of the

generating set. Contact Bredenoord for other technical information.

List of buttons and switchesThe generating set is fitted with the following buttons and switches.

Code Description

A10 Genset controller

A2.2 Genset controller expansion module

A2.3 Genset modbus module

F2 Generator measuring voltage

F2.3 Heating control panel

F2.6 Airco control panel

F2.11 Cooling fan motor protection switch

F2.12 Liquid side engine room extraction fan motor protection switch

F2.13 Battery side engine room extraction fan motor protection switch

F3.1 Control overcurrent protection

F3.5 Generator circuit breaker (GCB) control overcurrent protection

F3.6 Work light overcurrent protection

F3.7 Battery charger overcurrent protection

F3.8 Battery charger overcurrent protection

F3.9 Terminal strip X31 overcurrent protection

F4 Connecting rail measuring voltage

F5 Engine heater circuit breaker

F5.7 Power output safety switch

Q1 Master switch

Q2 Left distribution switch

Q3 Centre distribution switch

Q4 Right distribution switch

S18 Mode selector switch

S28 Generator - mains selector switch

Annexes 81

Code Description

S34 Generator monitoring bridging switch

S36 50 Hz - 60 Hz selector switch

Connection strip contact points

Potential-free contacts

Terminalstrip

Connectionpoint

Description Function

1 COM

2

Status message of position of generator circuit breaker (GCB)

NCNC

3 COM

4

Status message of position of generator circuit breaker (GCB)

NONO

81 COM

82 NC

83

Main alarm

NO

84 COM

85 NC

86

Pre-alarm

NO

87 COM

88 NC

89

In operation

NO

90 COM

91 NC

X14

92

Interlock active

NO

Annexes 82

Non-potential-free contacts

Terminalstrip

Connectionpoint

Description Function

13 COMX8.1

13.1

Generator circuit breaker (GCB) switched off

NC

9 COM

10

Status of master switch (MCB)

NO

11 COM

X10

14

Start/stop generator remote control

NO

1X25

2

Power supply for controller programming mode when generating set is switched

off

• COM: common

• NC: normally closed

• NO: normally open

Annexes 83

Maintenance record plate

The maintenance record plate is mounted on the cooling and heating control cabinet in the control

cabinet. The maintenance work is signed off on this maintenance record plate. This plate also

indicates when the next service must be carried out (in terms of total operating hours).

Annexes 84

EC Declaration of Conformity

This machine fully complies with the legal requirements pertaining to integrated safety laid down

in the European Machinery Directive. We can therefore issue the following EG declaration for your

machine.

The CE nameplate on the machine and the Declaration of Conformity below

indicate that the manufacturer has followed the ‘principles of integrated safety’

in conformity with the Machinery Directive.

This includes:

1. designing to eliminate or reduce the risks to the extent possible

2. implementing the necessary protection measures for risks that cannot be eliminated

3. informing the user (through this manual and stickers) about the residual risks

EC Declaration of Conformity

IN ACCORDANCE WITH ANNEX II(A) TO DIRECTIVE 2006/42/EC

We: Bredenoord B.V.

declare, entirely under our own responsibility, that the product:

Brand: Bredenoord

Type: 1020981

Model: 500 kVA

to which this declaration relates is in conformity with the provisions of the following directive:

Machinery Directive: 2006/42/EC

Noise Emission Directive: 2000/14/EC

and is in conformity with the following standards and/or other normative documents:

NEN-EN 12100-1 and -2 Safety of machinery

NEN-EN-ISO 20607 Safety of machinery - Instruction handbook

NEN-EN-ISO 8528-13 Reciprocating internal combustion engine driven alternating current

generating sets - Part 13: Safety.

NEN-EN-IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1:

General rules.

Drawn up: Bredenoord B.V. Zutphensestraat 319, Apeldoorn, The Netherlands

September 2018

H. Keurhorst (technical director)

Annexes 85

Bredenoord B.V.

Zutphensestraat 319

7325 WT Apeldoorn

The Netherlands

00800-55008800

https://www.bredenoord.com

[email protected]

container generating set - bredenoord

Documents