installation recommedations_010902 ing

8/16/2019 Installation Recommedations_010902 Ing

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TRITON POWER Sept. 02 2

Introduction Triton Generating sets are designed to

be commissioned, when delivered,as soon as the necessary coolingwater, antifreeze, fuel, lubrication

oil and fully charged battery areprovided.

Care should be taken to perform

more frequent maintenance indirty and dusty environments inorder to keep the generating set in

good working condition.




Safety General

The generating set is designed to be safewhen used in the correct manner.

However responsibility for safety rests with

the personnel who install,use and maintainthe set.

If the safety precautions are followed, thepossiblity of accidents will be minimized.

Before performing any procedure or operatingtechnique,it is up to the user to ensure that itis safe.


http://slidepdf.com/reader/full/installation-recommedations010902-ing 4/97TRITON POWER Sept. 02 4

Safety Fire And Explosion

Fuels and fumes associated withgenerating sets can be flammable andpotencially explosive.

Proper care in handling these materialscan dramatically limit the risk of fire orexplosion.

However , safety dictates that fully

charged fire extinguishers are kept onhand.

Personal must know how to operate them.



Safety Mechanical

The generating set is designed withguards for protection from movingparts.

Care must still be taken to protectpersonnel and equipment from othermechanical hazards when workingaround the generating set.

Do not attempt to operate thegenerating set with the safety guardsremoved.



Safety Chemical

Fuels, oils, coolants,lubrications and batteryelectrolyte used in this

generating set are typicalof the industry.

However, they can behazardous to personal if

not treated properly.



Safety

Electrical Safe and efficient operation of electrical

equipment can be achieved only if the equipmentis correctly installed, operated and maintained.



Gen-Set Selection-1

You should answer the questions whichare given below when you select theGen-Set.

Ambient air temperature ?

Altitude ?

Estimated running hours per year ? Environment ?

Non hazardous / Dusty / salt Laden / Other




Gen-Set Selection-2

Have the load acceptance capabilitiesbeen communicated to the customer ?(yes / no)

Alternator type / model Installation type

Return fuel tank capacity Is spill to day tank or bulk tank fuel

level above injector level ?




Main parts of GeneratorsStart & Control Panel

SmartPower

a

Alternator

a

Engine

(Diesel,Gas,Gasoline)

Base Frame




General Generator View-1Start vs Control Panel Turbocharger Air Filter

Radiator

DieselEngine

Alternator

Battery

OutputCircuit

Breaker Steel BaseFrame

StarterFuel Tank




General Generator View-2

Lifting BracketEmergency Stop Button

Canopy

Water Proof &

Sound Proof




General Generator View-3 Air Inlet

Generator Label

Model

Power Output,

Prime , Standby

Cos ø, Volt, Amps,Hz

Product Date,

Group Weight

Serial Number

Control Panel




Diesel Engine The diesel engine powering the

generating set has been choosen for itsreliability and the fact that it has beenspecifially designed for powering sets.

The engine of the heavy duty industrialtype with 4 stroke is compressionignition and fitted with all accessories toprovide a reliable power supply.

These accessories include, among other,a cartridge type air filters and amechanical or an electronic enginespeed governor.

Lenoir Engine

1870




Engine Electrical System The engine electrical system is 12

Volts DC if gensets power outputis less than 200 kVA or 24 VoltsDC if gensets power output is

more than 200 kVA. Negative is ground/earth.

This system includes an electricengine starter, a battery and abattery charging alternator.

For 24 Vdc system, two batteriesare given which are connected

series..




Cooling System The engine cooling system is

either air cooled or water cooled.

The air cooled system consists ofa high capacity fan to pull cool air

across the engine to cool it. The water cooled system is

comprised of a radiator a pusherfan and thermostat.

The alternator has its owninternal fan to cool the alternatorcomponents and windings.




Alternator

The output electrical power is normally produced bya screen protected and drip-proof, self exciting, selfregulating, brushless alternator fine tuned to theoutput of this generating set.




Fuel Tank And Baseframe The engine and alternator

are coupled together andmounted on a heavy dutysteel baseframe.

This baseframe includes afuel tank with a capacityof approximately 8 hoursoperation at full load.

(Except for gen-set poweroutput above 710 kVa )

Baseframe Fuel Tank




Vibration Isolation The generating set is

fitted with vibrationisolators which aredesigned to reduce enginevibration being

transmitted to thefoundation which thegenerating set is mountedon.

These isolators are fittedbetween theengine/alternator and the

baseframe.

VibrationIsolators




Silincer And Exhaust System

An exhaust silencer isprovided loose forinstallation with thegenerating set.

The silencer andexhaust system reducethe noise emission fromthe engine and candirect exhaust gases tosafe outlets.




Control System One of several types of control

systems and panels may befitted to control the operation ,output of the set and to

protect the set from possiblemalfunctions.

Control Module




Installation,Handling And Storage

General

Once the size of the generating set and anyassociated control systems or switchgear havebeen established, plans for installation can beprepared.





Canopies

Installation and handlingis greatly simplified whenthe generating set hasbeen equipped withcanopy.

The canopy also givesprotection from the

elements and protectionfrom unauthorized access.

ASM 5





Moving the generating set

The generating sets baseframe is designedfor ease of moving the set.

Improper handling can seriously damagecomponents.

Using a forklift, the generating set can belifted or carefully pushed / pulled by thebaseframe.

If pushing, do not push the baseframedirectly with fork.Always use wood betweenforks and the baseframe to spread the loadand prevent damage.





Location

Selection alocation for thegenerating set can

be the mostimportant part ofany installation

procedure.




The following factors are important indetermining the location-1

Adequate ventilation

Protection from elements such asrain,snow,sleet,wind drivenprecipitation, flood water, directsunlight, freezing temperatures orexcessive heat.

Protection from exposure toairborne contaminants such asabrasive or conductive dust, lint,smoke, oil mist, vapors, engineexhaust fumes or othercontaminants.

Floor of generating set room mustbe smooth and strong.

Protection from impact from fallingobjects such as trees or poles,orfrom motor vehicles or lift trucks.




The following factors are important indetermining the location-2

Clearance around the generating setfor cooling and access for service: at

least 1 meter around the set and atleast 2 meter headroom above the set.

Access to move the entire generatingset into the room. Air inlet and outletvents can often be made removeable

to provide and access point. Limited access to unauthorized

personnel.

If it is necessary to locate thegenerating set outside of the building,

the generating set should beencloused in a canopy.

A conapy is also useful for temporaryinstallations inside or outside thebuilding.




Foundation’s Vibration Isolation

The generating setis shippedassembled on arigid baseframethat precisely alignsthe alternator andengine and needs

only be bolteddown to a suitableprepared surface.




Foundation-1 A reinforced concrete pad provides a rigid support to prevent

deflection and vibration.Typically the foundation should be 150mm to 200 mm (6 to 8”) deep and least as wide and long as thegenerating set.

The ground or floor below the foundation should be properly

prepared and structurally suited to carry the weight of thegenerating set.

If the generating set is installed above the ground floor,thebuilding structure must be able to support the weight of the

generating set, fuel tank and accessories. If the floor may be wet from time to time such as in a boiler

room, the pad should be raised above the floor. This willprovide a dry footing for the generating set and for those who

connect, service or operate it.It will also minimize corrosive action on the baseframe.




Foundation-2Start & Control PanelEngine (Diesel,Gas,Gasoline)

Base Frame

a

SmartPower

a

Alternator

1 5 0 - 2 0 0 m m

Foundation




Combustion Air Inlet Air for engine combustion must be

clean and as cool aspossible.Normally this air can bedrawn from the area surrounding thegenerating set via the enginemounted air filter.

However, in some cases due to dust,dirt or heat, the air around the set isunsuitable. In these cases an inletduct should be fitted. This ductshould run from the source of cleanair ( outside the building, another

room, etc.) to the engine mounted airfilter. Don’t remove the air filter andmount it at a remote location as thiscan increase the possibility of dirtleaking through the ductwork andinto the engine inlet.




Cooling And Ventilation-1 The engine, alternator and exhaust

piping radiate heat which can resultin a temperature high enough toadversely effect the performance ofthe generating set. It is thereforeimportant that adequate ventilation isprovided to keep the engine and

alternator cool. Proper air flow, as shown in figure,

requires that the air comes in at thealternator end of the set, passes overthe engine, through the radiator and

out of the room via a flexible exhaustduct. Without the ducting of the hotair outside the room, the fan will tendto draw that hot air around and backthrough the radiator, reducing thecooling efficiency.




Cooling And Ventilation-2 Sharp corners on the

radiator, hot air outletchannel or its chimney mustbe avoided. Somerearrangements to turn

thrown air should be done. The air inlet and outlet

openings should be largeenough to ensure free flow ofair into and out of theroom.As a rough guide theopenings should be each atleast 1.5 times the area ofthe radiator core.




Cooling And Ventilation-3 Both the inlet and outlet

openings should have louvres forweather protection. These maybe fixed but preferably should bemovable in cold climates so thatwhile the generating set is not

operating the louvres can beclosed.This will allow the room tobe kept warm which will assiststarting and load acceptance.

For automatic starting generatingsets if the louvres are movable*they must be automaticallyoperated. They should beprogrammed to openimmediately upon starting theengine.

P t ti i t f t i




Protection against frost is as

follows..

Antifreeze /Water Protection Down To(% by volume) (°C)

50/50 -3560/40 -40




Boil Point

020

40

60

80100

120

140

160

180

0 1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

1 0 0

Boil Point

B o i l

P o i n t

° C

% Antifreeze




Frost Point

-80

-70

-60

-50

-40-30

-20

-10

00 10 20 30 40 50 60 70 80 90 100

Frost Point

% Antifreeze

F r o s

t P o i n t ° C




Exhaust-1 The purpose of the engine exhaust system

is guide the exhaust to outside of the gen-set room and height where the fumes andodours will not become an annoyance orhazard and reduce noise.

A suitable exhaust silencer must be

incorporated into the exhaust piping toreduce the noise level from the engine.

In designing an exhaust system, the primaryconsideration is not exceed the allowableback pressure permitted by the engine

manufacturer.

Excessive back pressure seriously affectsengine output, durability and fuelconsumption.




Exhaust-2 To limit the exhaust back pressure,

the exhaust piping should be asshort and straight as possible.

Any required bends should have acurve radious of at least 1.5 timesthe inside diameter of the pipe.

A flexible connection between theexhaust manifold and the pipingsystem should be used to preventtransmission of engine vibration tothe piping and the building and to

allow for thermal expansion and anyslight misalignment of the piping.




Exhaust-3 The exhaust pipes should be

supported by the building in order

to prevent the dead-weightcarried by the engine manifoldand turbocharger.For that,stretching elements should beused.

Exhaust system componentslocated within the generator roomshould be insulated to reduce heatradiation and noise level.

Pipes and the silencer, whetherlocated inside and outside thebuilding, should be located wellclear of any combustible material.




Exhaust-4 The outer end of the exhaust

pipe, if horizontal, should becut at 60° to the horizontalor fitted with a rain hood orcap if vertical to prevent rain

or snow from entering theexhaust system.

The exhaust pipe must notbe connected to other

generating sets exhausts. Exhaust pipes must be made

up black iron pipe.




Fuel System The fuel system for the generating set must be capable pf

delivering a clean and continuous supply of fuel to the engine.For most installations, this include a small day tank, a bulkstorage tank and fuel lines.

Do not smoke or allow sparks, flames or other sources of

ignition around fuel. Fuel vapours and oil vapours are explosive.

For systems which have two or more tanks, the tank or tankswhich supply fuel directly to the engine are termed “Day Tanks”

and other tanks in the system, which do not directly supply fuelto the engine, are termed “Bulk Storage or Make-Up Tanks.”




Typical Fuel Installation Using a base tank

fed from a bulk tank

1. Fill cabinet withoverfill alarm andgauge

2. Tank fill line

3. Vent

4. Contents gauge

5. Bulk storage tank

6. Sludge drain

7. Bund tank

8. Outlet valve

9. Supply line to daytank

10. Electric fuel transferpump

16. Level gauge

17. Drain18. Leakage alarm

unit (optional)

19. Fuel filter

20. Engine fuel pump

11. Electric fuel shutoff valve

12. Optional band13. Day tank incorporated in

baseframe

14. Float control switches

15. Manual fill and vent




Day Tank Day tanks provide a

readily availablesupply of fueldirectly to thegenerating settherefore should belocated within thegenerator room.

The baseframe isdesigned to containa day tank up to 700kVA.

Day tank




Day Tank-2 Day Tanks

Must avoid possibility of HydraulicLock

Must facilitate plumbing withinsupply and return line restrictionlimitations

Fuel level must be no more than 1.5meters [5 feet] above or 1.8 meters[6 feet] below crankshaft centerline

Must be within 15 meters [ 50 feet]of engine

Must avoid sources of externalheating

Must provide for refueling access if no make-up tank or system isinstalled




Bulk Storage Tank-1

BulkStorageTank

For extended operation, a separate bulk fuel storage tank isrequired.

The bulk tank should be generally located outside the buildingwhere it will be convenient for refilling, cleaning and inspection.Ifshould not, however, be exposed to freezing weather because fuelflow will be restricted as viscosity increases.

A sludge drain valve should be installed at the low point to allow

removal of water and sediment on a regular basis.




Bulk Storage Tank-2

Must include valves to control and shut off make-up flow

Must include equipment to prevent Day Tank Overfilling

Transfer piping must not be capable of siphoning fuel from day tank

1 8

11 14




Tank Materials Must be clean

Must not rust, corrode or contaminate fuel No galvanized steel tanks

An aluminum or protective coated steel (phosphate or terneplate) tank is

common. Galvanized steel tanks or materials that include zinc must notbe used. Fuel can interact with the coating to form oxidized flakes thatcan plug filters and injectors. Interactions between fuel additives andtank materials must also be considered when selecting a tank.

If the fabrication process includes welding, where debris such as slag

could accumulate in the tank, appropriate cleaning after fabrication isrequired.

Tank materials that permit heat in the fuel to be dissipated may reducethe required size of a fuel cooler.




Fuel Lines The fuel lines can be any fuel compatible material

such as steel pipe or flexible hoses that will tolerateenvironmental conditions.

Flexible piping should be used to connect to the

engine to avoid damage or leaks caused by enginevibrations.




Tank Fittings-1Drain Opening

Must facilitate removal of accumulated water, dirt, etc.

A pipe plug is generally unsatisfactory for this function because of theskill required to remove and reinstall it without releasing excessive

fuel. A drain area that includes a well or settling basin isrecommended because it tends to concentrate the contaminants.Typically the bottom of a fuel tank has rounded corners and slopes ata 2-degree angle toward the drain opening.

17




Tank Fittings-2Breather

Must prevent backpressure on fuel return lines Must allow pressure relief while filling or transferring fuel

Must be above the tank’s maximum fuel level

Must be protected from entry of dirt and water Must conform to statutory requirements




Tank Fittings-3Fill Opening

Must be above maximum fuel level Fill Neck must provide space for thermal expansion

Cap must be attached to the tank

Must minimize fuel agitation

The fill opening should be large enough to permit the tank to be filled in 2or 3 minutes. The cap should be arranged to prevent mud or dirt fromdropping into the tank when the cap is removed.

A safety or captive chain is recommended for caps that are not otherwiseattached to the tank.

The fill neck should extend into the tank an equivalent of 5 percent of thevolume to provide space for thermal expansion.




Tank Fittings-4Fuel Pump Suction Line Connection

Pick up must be at least 25 mm [1 in] above bottom center oftank

Must facilitate required flow rate

Must have a check valve to prevent fuel from draining back to

Day Tank and to prevent flow into cylinders when engine is notrunning.

A bottom outlet fitting may be prone to damage, so a suitable

braced drop tube from the tank top may be preferred. Air leaksin this connection can cause erratic engine behavior, so care inselection and installation is required. A suction screen may be auseful addition if it can be easily accessed for cleaning.

Day Tank to Engine




Day Tank to Engine

(Fuel Supply Line) Must have restriction less than or equal to engine data sheet

requirements Must have a check valve to prevent fuel accumulation in

cylinders when engine is stopped

Must avoid sources of external heating

Engine to Day Tank




Engine to Day Tank

(Fuel Return Line)

Must have restriction less than or equal to engine data sheetrequirements

Must have a check valve to prevent fuel accumulation incylinders when engine is stopped if this accumulation is possible

via the fuel return lines

Fuel Shut-off devices not permitted at this line

Must avoid sources of external heating




Fuel Return Line Connection

Must allow separation of fuel and vapor or gases in theexpansion space above the normal fuel level

Must minimize fuel agitation

If fuel level can be above the level of the crankshaft, a check

valve is required in the fuel return line If Fuel level can be below the level of the crankshaft, the

discharge must be below the lowest fuel level in the day tank.

The return line discharge should be pointed away from thebreather and the suction areas.

Flowing the return against a sidewall or baffle at a shallow anglecan sometimes minimize agitation.




Fuel Heating and Cooling-1 Fuel Inlet Temperature must not exceed Engine data sheet requirements

Fuel heaters are required if ambient temperature can be below the fuel cloud point

Power loss can be expected when fuel temperature is greater than 49oC [120oF] (some manufacturer recommended that it is start a power loss when fueltemperature is greater than 40°C)

In general, fuel at temperatures greater than or equal to 71oC [160 oF] shouldnever be supplied to the engine. Since fuel is used to carry away heat on someengine models, fuel cooling may be necessary to keep inlet fuel within the

specified operating range. Duty cycle, size of the day tank, and heat rejectionfor the particular engine are all factors which must be considered when sizinga fuel cooler. Consult the engine data sheet for specific heat rejectionrequirements.




Fuel Heating and Cooling-2Fuel coolers should be installed only in the return lines. DO NOT plumb the heat

exchanger in the fuel supply (Day Tank to Engine Fuel Pump) lines. Typicallythe inlet (hot fuel) is lower than the outlet (cooled fuel) to take advantage of

natural convection circulation.

Mount the fuel cooler and all associated wiring and plumbing in a manner that

they are protected from vibration, weather and external sources of heat.Fuel

Coolers may utilize a variety of methods to circulate cooling air through the

heat exchanger, including electric or hydraulic motors or drive belts. If the

engine is equipped with a fan clutch, an alternate means of circulating cooling

air should be considered.




Lubrication Oil Oil system of diesel engine is one of the most important

elements of the engines.Correctly made engine overhaul (thissubject includes oil change periods,paying attention aboutselection the true type of oil) prolongs the life of the engineand it decreases the life cycle cost of the engine.

The American Petroleum Institute (API) , The American SocietyFor Testing and Materials (ASTM) and Society Of AutomotiveEngineers (SAE) has developed and preserved a system in orderto classify the lubrication oils for their performance categories.

In oil performance recommendations modifiers, according totheir MIL specifications, has been given in paranthesis.




Trade Oil Categories CF-4 (It has no modifier property) and similar oils are being used for four

stroke, high velocity diesel engines. API CF-4 oils contain properties above theCE category oils.These oils can be used for CE oils.

CE (It has no modifier property) oils with their high cover properties as certainprotection against abrasion, low oil consumption and better protection againstprecipitation.These oil have been produced in turbocharge and supercharge type

since 1983 in low speed, high speed and overloading conditions and it has beendesigned as serious service oil in diesel engine applications.

CD-11 (MIL-L-2104D/E) has been chosen for two stroke diesel engines categoryand it has been designed for high service conditions since it necessitates highlevel of control because of the precipitations and abrasions.

CC (MIL-L-21048) type of oil as certain protection from precipitation and CC oilshas been designed to work at high temperatures more easily.




Recommended SAE Viscosity Levels

AmbientTemperature

Lubrication Recommendation For




Lubrication Recommendation For

Cummins

Cummins recommends that high quality SAE 15W/40

high service engine oil in diesel engines are used. The minimum API oil quality levels recommended for

use is CE or CF-4.CD/SF oil can be used in areaswhere CE or CF-4 oil is not yet available, but the oilchange interval must be reduced to one half theinterval given in the maintenance schedule.

If naturally aspirated engines or turbocharged

engines are being used as excess power (stand-by)CD oil may be used without thinking of the oilchanging periods.

Lubrication Recommendation





For Perkins

For Perkins engines, good quality lubrication oil should be used

as shown below ;

For naturally aspirated engines API CC/SE,MIL-L-4612

API CC/SE, MIL-L-2104D,ACEA

For naturally aspirated engines working in high service conditions API CC/SE, MIL-L-2104D,CCMC D4 *

For turbocharged engines API CC/SE, MIL-L-2104D,CCMC D4 *

* It is not recommended for light loads and first 25/50 workinghours.






For John Deere

John Deere engine manufacturer recommends the

following lubrication oils API CE or API CD

CCMC D4 or CCMC D5






For Yanmar

To help assist engine running, all engines are

dispatched with an initial fill lubricating oil whichmust be changed after 50 hours.

Yanmar engine manufacturer recommends the

following oils; API CC or CD






For Lister Petter

To help assist engine running, all engines are

dispatched with an initial fill lubricating oilwhich must be changed after 100 hours.

Lister Petter engine manufacturer

recommends the following oils; API CC

DEF 2101 D MIL-L-46152 B

MIL-L-2104 B





For Deutz

Deutz engine manufacturer recommends the

following oils; API CF-4,CG-4,CH-4

ACEA E1-E3-96 + E4 -98




For MTU

MTU engine manufacturer recommends the following

oils for 2000 and 4000 series engines; API CG-4

ACEA E2-96

ACEA E3-96




Batteries-1 Warnings :

Do not smoke or allow sparks, flames or other sources of ignition aroundbatteries. Hydrogen gas generated by charging batteries is explosive.

Wear an acid resistant apron and face shield or goggles when servicing thebattery. If electrolyte is spilled on skin or clothing, flush immediately withlarge quantities of water.

Take out the metalic things in your wrist and protect your wrist and hand. Disconnect the nattery negative (earth) lead first and reconnect last.

Always ensure that battery charging is carried out in a well ventilated area.

The starting batteries should be located as close as possible to the

generating set while still being accessible for servising.This will preventelectrical losses from long cables that could impact on the engine startingcapability of the batteries.




Batteries-2 First filling of acid water to the battery

Take out the protective cover above the taps and tear down the air outlet

taps. Fill the battery with a clean accumulator acid having a density of 1280 at

20°C until the point 15 mm above plates.Battery and acid temperature mustabove 10°C.

Let the battery to stand still 15 minutes. After that point battery pockets will

start to become heated and gas bubbles will rise at the surface ofelectrolyte.

Attach the air outlet taps to their place.

After waiting at least 15 min. Control the battery with a hydrometer.

Minumum charge time is 6 hours.

If the charge voltage and electrolyte level does not increase in at leastone hour period that means battery has been charged.

Control the electrolyte level after two hours from the charge and ifnecessary add distilled water so that it is 10 mm. Above plates.




Batteries-3 Batteries Maintenance

Keep the top of the battery and its teminals clean Cover the cattery teminals and its connections with vaseline.

Tighten the teminals but not tighten it hardly.

Control the electrolyte level periodically. It must be 10mmabove the plates.

Control the abrasion in the charge alternator belt and checkperiodically the belt tension according to the producer’s

recommendation. Ensure that your battery in not uncharged.




Batteries-4 Testing the batteries

Conduct an inspection every time before testingthe battery.

A white powdered element causes abrasion to

the pole-heads, its surroundings and theconnections. Remove the connections andwash them with hot water to purify the

oxidation. Reconnect it and coat with vaseline. Check if any untightened connections exist.




Batteries-5 Hydometer Test

Sulphuric acid density and its charge situation hasbeen determined by using a hydrometer. Do not add distilled water

Keep the barrel part of the equipment in the verticalposition and pull on the sufficient amount of electrolyte.Inside the tube there must be a free float and it shouldbe readable at the eye level.

Evaluation is as the following ;

Between 1.270 and 1.280 density level is fully charged

Between 1.220 and 1.230 density level is half charged

Between 1.150 and 1.220 density level is low charged.




Batteries-6 Free Maintenance Batteries

Ensure that all battery connections arecorrect and batteries are always changed.

After that there is not any maintenanceprocedure for this batteries.




Electrical Connections-1 Cabling

Due to movement of generating sets on their vibrationmounts, the electrical connections to the set should be madewith flexible cable.

The cable should be protected by laying it in a duct or cable

tray The cable must be suitable for the output voltage of the

gen-set and rated of the set. In determining the size,allowances should be made for ambient temperature,methodof installation, proximity of other cables, etc.

All connections should be carefully checked for integrity.




Electrical Connections-2 Cable cross section selections

If the distance between load and generator is too length, voltage falling

at the load side can be too much at the transient current duration.

In this case you should calculate the cable cross sections with electricalformule which has been given below;

( )

(ohm/m)cableof Resistance:

(ohm/m)cableof Resistance:

Current:

(meter)lengthCable:

fallingVoltage:

3

X

R

I

L

e

XSin RCos I Le φφ +×××=




Electrical Connections-3 Loading

When planning the electrical distribution system, it is importantto ensure that a balanced load is presented to the generatingset.If loading on one phase is substantially higher than the otherphases, it will cause overheating in the alternator windings,imbulance in the phase to phase output voltage and possible

damage to sensitive 3 phase equipment which is connected tothe system.

Ensure that no individual phase current exceeds the currentrating of the generating set.

For connection to an existing distribution system, it may benecessary to reorganize the distribution system to ensure theseloading factors are met.




Electrical Connections-4 Power Factor

The power factor (Cos ø) of the connected load should bedetermined. Power factor below 0,8 lagging (inductive) canoverload the generator. The set will provide its kilowattrating and operate satisfactorily from 0,8 lagging to unity

power factor (1,0). Particular attention must be given to installations with power

factor correction equipment such as capacitors to ensurethat a leading power factor is never present.This will lead to

voltage instability and may result in damaging overvoltages.

Generally whenever the generating set is supplying the loadany power factor correction equipment should be switch off.




Engine Jacket Water Heater Heater warms up the jacket

water of the engine whenthe generating set is notworking.

Jacket water heater is usedin order to start up thegenerating set more easilyand take the load. In

automatic generating sets jacket water heater isstandard. In manual type gen-sets it is an option.

Hot outletCold inlet




Towing (Portable Gen-Sets) Inspect tyres for condition and proper inflation.

Check that all tail lights are operating properly andthat all reflectors are clean and functional.

Whenever towing a mobile generating set, remember

that manoeuvrabilty and stopping distance will beaffected by the weight of the trailer.

Do not permit personnel to ride on the mobile set. Do

not permit personal to stand or ride on the drawbaror to stand or walk between gen-set and towingvehicle.




Gen-Set Control Systems To control And monitor the generating set, an

electronic control system has been used. Depending on the requirement of the set,one of

several different different standart control systems

may be fitted. Control panel provides a means of starting and

stopping the gen-set, monitoring its operation and

output, and automatically shutting down the set inthe event of a critical condition arising such as lowoil pressure or high engine temperature.




Panel Equipments Before starting or running

the generating set, theoperator should becomefully acquainted with theinstruments and controls.

The instruments should beobserved from time to timewhile the generating set is

running so that anyabnormal readings can bedetected before problemsarise.




AC Voltmeter A voltmeter that indicates

the AC voltage generated atthe alternator outputterminals.

The reading indicated on thevoltmeter will vary

depending on theconnections made inside thealternator terminal box, thesetting of the voltage

regulator and the position ofthe voltage regulator and theposition of the voltmeterselector switch.




Voltmeter Selector Switch A selector switch is

allowing theoperator to selectvoltage reading

between phases orbetween a phaseand neutral.




AC Ampermeter An ammeter that

indicates the ACelectrical currentbeing delivered

which isdependent onthe connected

load. There arethree ammeterfor each phase.

F M (H )




Frequency Meter (Hz) A meter that indicates the output

frequency of the generating set. The

engine maintains a relatively constantspeed under governor control so asto provide the proper operatingfrequency of 50 Hz or 60 Hz whenthe generating set is operating at full

load.

In practice, if the generating set hasa manual governor control system, noload frequencies of approximately 52Hz or 62 Hz for 50 Hz and 60 Hzrespecttively, are considered.

The frequencies will fall to 50 Hz and60 Hz at full load as the set is loaded.

H R M t




Hours Run Meter A meter that indicates

the total number ofhours of generatin setoperation to aid in

maintenance.

W t T t G




Water Temperature Gauge A temperature gauge

connected to asensor in the engineto monitor engine

coolant temperature. Normal level of the

engine coolanttemperature isapproximately 85°C.(185°F)

Oil P G




Oil Pressure Gauge A gauge to monitor

engine oil pressure. On cold engines the

oil pressure will be

significiantly higheruntil the enginewarms up.

E St P hb tt




Emergency Stop Pushbutton A red lockdown push

button thatimmediately shutsdown the generating

set and will inhibitstart until thepushbutton has beenreleased by turning it.

B tt Ch L




Battery Charge Lamp In generating sets without

a charge alternator whenthe battery charge lamp ison,this indicates that thebattery charger is working.

This means that the batteryis being charged.

In generating sets with acharge alternator when the

battery charge lamp is on,it incidates that there is afault in the chargingprocess.

Alt t P t ti




Alternator Protection In our standart production,

the alternators in automaticoperation generating sets areprotected with a thermicprotector against overload.

In our standart production ofmanual operated generatingsets, the alternators areprotected against overload

and short circuit by a thermicmagnetic switch.

The Placement And Installation Of

Transfer Switch 1




Transfer Switch-1 Position the transfer switch near the emergency power panel

Locate the transfer switch in a place where it is clean, not over-heated,

and having a good ventilation. If the ambiant temperature is above 40°C, fuses and breakers will

open more easily.

There must be enough working place around the transfer switch.

Currents from the generating set must be distributed equally to the 3phase if possible. Current from one phase should not exceed thenominal current.

If the transfer switch panel is apart from the generating set, transferswitch must be placed as close as possible to the distrubutor panel. Inthis case power cables are drawn from generating set, mains panel andemergency power panel. Furthermore 8x2.5 mm² control cable mustbe drawn from the generating set control panel.

The Placement And Installation Of

Transfer Switch 2




Transfer Switch-2

G

kWh

Troubleshooting




Troubleshooting Alternator troubleshooting

Diesel engine troubleshooting

http://c/aaEGITIM%20DEPARTMANI/bil%20egitim%20slaytlari/Ingilizce%20Sunumlar/Troubleshooting.doc






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