koel logo - Manufacturer of Silent Generators in India, Delhi Silent
Contents
1. f JAKSON amp CO ELEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEELEEEEELEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEEEEEEEELEEEEFEEEEEEEEEEEEEEEEEEEEEEEEEEZEEF 006 im X 3 3 HVYSO TUI A8 Q3A0HddV NOLLVONNOS 9NDIVIN HOS S 90 20 1 3lva 18 Q330305 9 YONA TAID HNOA 9 AIGNIM ONIMVYG 39N3834338 V AINO SI 9 1 M 90 3H A8 NMYY02. I JAKSON amp CO FOUNDATION DETAILS AND GUIDELINES Ground base Foundation RCC PCC gt The foundation should be water leveled and at least 3 4 above the ground level to maintain cleanliness and avoid flooding The length and width of the foundation should be at least 600mm to 800 mm more than that of the DG set size i e 300mm on each side Check the foundation level diagonally as well as across the length and width Pleasereferto thefoundation drawing attached herewith page 3
3. Exhaust Piping The exhaust system must be designed to keep the resistance to hot gases back pressure as low as possible and load of the extended exhaust pipe silencer should not be on the engine manifold The following may please be noted There should not be any load or stress on the expansion bellow There should be proper support for the exhaust pipe Exhaust Pipes should be extended through proper flanges only Short bend should be avoided Always use proper size MS pipe G I Pipe and bend should not be used in exhaust piping 6 At the time of Genset Installation Please ensure proper alignment of exhaust silencer with respect to expansion bellow Exhaust pipe load should not come on Expansion bellow and it should not touch the roof body As per statutory regulations exhaust pipe has to be extended above the surrounding stack as below H h 0 2 x Vkva Where H Minimum height of exhaust stack h height of building Exhaust Pipe Details Engine Model Minimum exhaust Air Cooled pipe OD mm EA10 G1 EA16 G1 HA294 G1 HA394TCI G1 HA494TCIG1 63 HA694TCI G1 Engine Model Minimum exhaust Water Cooled pipe OD mm
4. JAKSON amp CO EARTHING SYSTEM An Earthing system is required for the protection of equipment and human being as per Indian electricity Rules 1956 Separate earth should be used for Genset body and neutral earthing 4 Nos earthing pits are required for 3 phase DG set 2 each for neutral amp body 4 Nos earthing pits are required for single phase DG set 2 each for neutral amp body The min distance between 2 earthing pits should be 2 0 meters An earth pit cover should be provided A watering pipe of 25mm with a funnel should be provided for each pit wherever depth ofthe earthing pitis not at water level Earthing system should be checked with meagre and resistance between 2 earth pits should be less then 10 The earthing plate pipe and strip size should be selected as per the rating of the DG set SDG Set rating Recommended Earth Strip Cable 5 82 5 KVA 8SWG Copper 100 250KVA 320 750KVA JAKSON amp CO TYPICAL EARTH PIT STATION ARRANGEMENT Chamber Cover SHIEK Work External Earth Connection Ground Lavel Mud Soil Layers of Salt amp Charcoal y Earth Pit GI Or Copper Plate 5
5. 777772777777777 7777777577777777737 777773777 77777377777 777777377777773777 7 777775777777777377777773777 77777775777777777 72777772777777777 77377 Engine give white Water mixed with fuel Check the reason and sort out or Contact to smoke manufacturer KOEL service dealer Dust entry in air inlet system Make necessary arrangement to stop dust entry CoTr any modification in air inlet arrangement Dirt clogged air cleaner Clean air cleaner air cleaner High exhaust back pressure 277 manufacturer recommendation Contact to manufacturer Poor quality of fuel Change the fuel and use good quality fuel Excessive fiel External internal fuel leakage Check for any leakage and recti consumption Faulty fuel Pump Contact to KOEL Service Dealer Engine overloading Ensure Load as per rating or manufacturer recommendation Check for any leakage and recti uet LUrroo a in air inlet arrangement any modification in air inlet arrangement Dirt Dirt clogged air cleaner ged air cleaner Clean air cleaner air cleaner Excessive oil consumption Top up with K Cool super plus without any modification in air inlet arrangement connection not proper Change the lube oil as per KOEL specification Low Lube oil Lube oil dilution Check and Change the lube oil as per KOEL pressure specification Dirt clogged lube oil filter Contact to KOEL Service Dealer Clogged oil passage Contact to KOEL Service Dealer Contact to KOEL Service De
6. Arigid foundation ensures the least vibration Sand Filling should be there around the foundation 18mm rubber matting must be used over the foundation to minimize the vibration effect and noise leakage Ensure that the foundation to support 1 5times of the total wet weight of the single generator and 2 times of the total weight for the multiple generators Please refer to the dimension of DG set for deciding the foundation length width and depth Note Please ensure that the foundation should not be made over any basement water tank or Sewer Line B Roof top Installation A rooftop installation requires proper planning and the structural design considerations for dynamic loading The weight of Silent DG set should be on Column and Beam through proper foundation The RCC foundation should be on the Beam or supported on two Beams gt ISMCChannelor MS I Section may also be used to cater the load of the DG set with the canopy Load of ISMC Channel or MS I Section should beonthe column ofthe building M S Sheetis to be provided at the bottom of the base frame of the Silent DG set for roof top installation
7. a Battery charging procedure Specific gravity of acid inside the battery should be 1 23 to 1 28 kg ltr Note Ifdry battery is supplied along with the DG set then initial charging of the battery is required gt If battery is kept ideal for 3 month then battery should be charged b Method to use battery gt If DG set is not in use for a long time then ensure that at positive terminal battery lead is not connected It should be connected at the time of the commissioning of the DG set gt Charged battery may be used for commissioning of DG set within 15 20 days else re charging of charged battery is required Always connect the battery with the proper battery charger The battery should be connected to the battery charger which is connected with 230V AC supply The Battery charger is provided with an AMF Panel Auto Mains Failure Panel under the standard scope of supply 230V AC supply is essential for battery charger operation Note Battery charger is not supplied with a std manual Panel So it is suggested that the DG set must run once a day for 15 20 minutes so that battery is charged by engine dynamo charging alternator Battery should not be kept ideal for 6 months c Precaution to be taken during handling of battery Donotcharge the battery at a wet a place Flame Candle and matchbox should not be used near charged battery Use hand gloves while handling the charged battery Electrolyte level should b
8. 2R1040 G1 683 3R1040T G1 3R1040TA G1 4R810TA G1 4R1040TA G1 4K1080TA G2 6K1080TA G2 6SL Series DV Series Note 1 If the extension of exhaust pipe is more than 5 meters above Genset increase pipe diameter by 13mm for every 3 meters 2 If no of bends are more than 4 increase the diameter of exhaust pipe and bend by 13mm for addition of each bend 3 Joining of Exhaust pipe for the both bank is not recommended In case of necessity common pipe diameter should be at least 10 higher and refer proper procedure Use of NRV valve and angle between chimni and pipe should be maintained before joining two exhaust pipe 4 Both the Exhaust pipe should not be connected opposite to each other Angle between pipe should be 30 to 45 Ww i W Ww wl W A W m wl i wi wi wl wj i NI wi Nu NN NN IQ wi wi W NN I wi wl wl NN IQ N W wl i NN ul N W i W W N iN W W wj ul iN i NN NN IQ iN iN wi i NN ul N wl NN wl i NN ul ul wi iN NN I Ww wl W W wl wi i NN wl Ww wi NN I Wj wi i i wl wi iN wi wl wi wi W N wl i wi NN NN wi wl N iN wl i wj N i NN wl wj wi iN wi wl Ww i Wl Nm wl i W A W No wl N W wl i wj I N i
9. ONIMVUC NOLIVONROJ JINN lyd 9 9 WHALONYLS Ag A301930 38 01 8 sv 43 NOISN3IAITQ x Im m 135 N39 400 d ANNOS 40 9NIMYYA NOLLVGNNOS 1 95 MAIN LNOHS R 79 IH130 M3N TENVAWIN C 3SVHd Wav ANI Z92 992 9 321A43S 09 NOSWVf 20105 bs im X J090WY3HL viz 998 0 S im 18 43434 Id AVM H108 9 9 0S1 Suvg 4 Vid ININ9L VAM009 OL VAM 0SZ 3 VIG WINE E VAM 00601 VAM 00L Z X VIO INWOL vANS 28 OL 4 X uve 40 3215 13S 90 INTIS 10 9 Jon s 3715 S dvd 903 FEV 40 3 im Nu Y i m X C x m e N I Oo im ep 8 decus 5 5 X 3 e 135 9d I c S 3 Y 06 m 3 0S p WW 009 135 9G 10 H19N31 N xsv NI JI 3 OL LON 3
10. W phase Check and recti JAKSON amp CO TROUBLE SHOOTING GUIDE FOR MANUAL PANEL Engine does not start by turning the starting key push botton provided on panel Checkconnection of battery Check Control MCB It should be in ON position Check the battery voltage at terminal 1 and 2 inside panel It should be 12 24 V If not check circuit or get the battery charged before making further attempts as battery may be weak The Engine cranks but fails to run Check the fuel supply line Check connection of fuel pipe at fuel tank it may open Air in fuel line 9 Faulty fuel pump Water mixed with fuel 9 Load is disconnected JAKSON amp CO TROUBLE SHOOTING GUIDE FOR AMF PANEL Engine does not start from the AMF panelin any mode Check the DC supply control MCBs and 3 Phase mains supply These should be in ON Position Check the battery voltage at terminal 1 and 2 in the AMF Panel It should be equal to 12V 24V If not get the battery charged before making further attempts as the battery is weak Check all control wires at control terminals in AMF panel Check battery terminals They should be properly tightened and should not be corroded Check LLOP connection it should be properly connected on engine terminal Check all wiring connection should be properly tighten and all should be in order as per drawing The battery connection may be loose or corroded Check and c
11. correct size for cable termination At notime loose wires should be tightened on to terminal busbar with bolts Crimping should be done with proper crimping tool Ensure tight crimping terminations to avoid overheating and burning of the cable and terminals Ensure proper bending radius is given to the cable to avoid excessive tension on cable termination Ensure that the weight of cables does not rest on alternator terminations Proper support to be provided from the ground separately through cable tray For 3 Phase 35 62 5 70 82 5 100 125 Al Cable Size 3 5 core sq mm 25 Copper cable size 16 3 5 core sq mm mm2 KVA 180 200 Al Cable Size 3 5 core sq mm 2x300 3x240 Copper cable size 3 5 core sq mm For 1 Phase KVA A Cable Size 2 core sq mm Copper Cable Size 2 core sq mm Note a Correct size cable glands should always be used for holding the cable b Control wiring should always be done with 2 5 sq mm copper cable c From 320 KVA to 625 KVA bus bar terminal box will be provided by customer JAKSON amp CO BATTERY CHARGING PROCEDURE
12. i NN wl wi iN wi wl Ww wi Wi N wl i W i NN m ul N iN S Wl wj ul N iN wi W NN wl wi i wl wl Ww wi i wl wl iN wi NN NN No ui N im W EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEECEEEEEEEEEEEECEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE X EEERZEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEZEEEEELEEEEEEEEEEEEZEEEEEEEEZEEEEEEEEEEEEEEEZEEEEEEEEEREEEEEEEEEZEEEEEEEEEEEEEEEEEZEEEEEEEEEEEEEEEFEZEEEEEEEEERN JAKSON amp CO Vv Vv Vv Y JAKSON amp CO 6 FUEL PIPING A supply and return fuel pipe is required in each DG set SDGs upto 625 KVA are provided with fuel tanks inside the acoustic enclosure Outside fuel tank will be provided as per requirement For fueltank inside the acoustic enclosure fuel piping is done by the manufacturer supplier However for Fuel Tank outside the enclosure fuel piping is to be done by the customer Size ofthe fuel piping should be 12mm upto 250 KVA DG set
13. temp altitide humidi Poor quality of fuel Change the fuel and use good quality fuel Choked fuel line Clean and clear fuel line is EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEREEEEEEEEEZEZEEEEEEEEEEEEEEEEZEEEEEEEEEEEEEEEEEEEEEEEZEEEEEEEEEEEEEEEEEEEEZEEEEEEEEEEZEEEEEEEEE N JAKSON amp CO Contd 227322323333323343323233432333333323333323 4323323333333 333332333323333323 433333333333 3323 32323333 333323 49133333 333333 333332333322 34333233323 3303233 333333323 3333733333 3330333 72332323 332333 333333333323 3323723 332323 32332233223233223277 2277 Water mixed with fuel Check the reason and sort out or Contact to manufacturer KOEL service dealer Change the fuel and use good quality fuel Engi
14. 1 23 1 28 kg ltr Check Fan belt tension Check battery charger Drain the water from fuel tank weekly during winters Check all nuts Bolts Engine Alternator foundation bolts tightness at the time of commissioning then monthly Check for any loose connections at the time of commissioning then monthly Use K cool super plus Lube K oil Premium and spares as per KOEL specification and purchase from authorized KOEL service dealer Refer Engine maintenance manual for routine and daily maintenance check Study user manual in detail before usage Keep good ventilation which is essential to keep the air cool and clean Use appropriate tools and equipments which are required to carry ot any service Ensure all nuts screw pipe connections and covers are properly tightened Ensure that sufficient diesel fuel oil in the tank amp lube oil in the engine for specification grade of oil amp coolant refer to O amp M Check the battery codition and connections Check earthing of the generator set Apply load on the genset gradually Carry out maintenance repairs amp overhauling of the genset as per recommended schedules in the user manual Call on the authorised service dealer for servicing amp maintenance work Please refer maintenace maual before doing any maintenance work Cable entry hole if not in use should be properly closed DON Ts Do not Repair Service any part when set is running Never operate the genset with any parts or duct
15. AL PANEL TROUBLE SHOOTING GUIDE FOR AMF PANEL SAMPLE WARRANTY CERTIFICATE D SELECTION SITE Proper space should be there for placement and opening of doors of the Silent DG set There should be atleast 1 5 meter free space around the DG set for proper operation and maintenance There should be cross ventilation of air to ensure proper cooling of DG set Exhaust gases and hot air discharge should not re circulate inside the acoustic enclosure canopy If Genset is to be installed in the room please ensure proper cross ventilation and surrounding space There should be no restriction for fresh air suction and hot air discharge If 2 nos DG sets are installed at the site ensure that hot air outlet of the one DG set does not become the fresh air intake of the 2nd DG set If Genset is to be installed in the basement please ensure ventilation with respect to Air requirement and clear space for every maintenance Distance between two SDG set should be minimum 3 meters A low height shelter for the Silent DG Set should be avoided It should not obstruct the hot air outlet It is preferable t
16. B C Class M S pipe 19 mm 25mm I D is recommended For fuel piping above 250 KVA DG sets MS pipe should be used with proper welded joints Stop valve and flange should be used in supply line to engine near fuel tank for Fuel Tank mounted outside PRECAUTIONS TO BE TAKEN FOR FUEL PIPING AND FUEL SYSTEM Never use GI pipes in fuel piping of DG set Joints should be welded and never threaded Pipe should be above ground level with proper MS support Alljoints should be tested for any seepage or leakage For 320 KVA and above DG sets Fuel Tank height should be such that lowest level of Fuel Tank is above Diesel pre filter height 123235 5333234543232343233324323333432323343232333323333323332333323333323332323333333333333 3333723333723 332323332333 0333333333323 933333 3333 3340323333 933323 9333333 3333334933333 49322333 0323333340333 23 133323 332333 3333324233323 332323 332333333327 CABLING It has been our experience that most electrical failures are caused by overheating due to loose thimbling or undersize cables Please use cable of correct size to carry full load current and thimble of
17. BY KIRLOSKAR We can achieve excellent performance from a Silent DG set if proper care is taken during its installation The following suggestions shall help you to achieve optimum performance from the D G Set ee j gt z akPowER JAKSON amp CO KIRLOSKAR For Assistance Please contact our customer care at C 266 267 Mayapuri Industrial Area Phase II New Delhi 110 064 Mobile No 9871590738 9871590745 Phone No 011 28114072 D 28111510 28113231 Fax No 28113149 e mail jaksonco jakpower com jakson service jakpower com In case you are not satisfied kindly register your complaint to Mr Gopi Nathan Mob 9910448420 Note 1 Please always sign the report made by our Service Engineer Warranty is applicable for two years for engine amp alternator only subject to use of Kirloskar K Oil Premium Kirloskar genuine filters K cool super plus and services sourced through KOEL authorized Service Dealer JAKSON amp CO JAKSON amp CO DESCRIPTION SELECTION OF SITE FOUNDATION DETAILS GUIDELINES Ref Drawing For Foundation of Gen Set EARTHING SYSTEM EXHAUST PIPING FUEL PIPING CABLING BATTERY CHARGING PROCEDURE SUMP CAPACITY CHECK UP BEFORE STARTING THE DG SET ROUTINE MAINTAINANCE OF SDG SET PRE COMMISSIONING CHECK ROUTINE CHECK POINTS DO S amp DON T S TROUBLE SHOOTING ENGINE TROUBLE SHOOTING ALTERNATOR TROUBLE SHOOTING GUIDE FOR MANU
18. ELEEEEEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEEZEEEEELEEEEEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEEZEEEEEELEEEEEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEIJ JAKSON amp CO 277 aso soo NN NN e e C NN dee lt TTT e ul NN EN NN NN m NN NN EM EN NN NN PRE COMMISSIONING CHECK Whenever you want to call a Service Engineer for commissioning kindly ensure that Installation work has been completed i e foundation earthing exhaust pipe job has been completed with proper supports if ex
19. EZEEEEEEEEZEEEEEECEEEEEEEEEEEEZEREEEEEEEEEEEEEEZEEEEEEEEEEEEEEEEEZEEEEEEEEEEEEEEEFEEEEEEEEEEER JAKSON amp CO SUMP CAPACITY LITRES AIR COOLED EA10 G1 EA16 G1 HA294 G1 HA394TCI G1 HA494 TCI G1 HA694TCI G1 Cee pe CNN Lts WATER COOLED Engine 2R1040 G1 3R1040T G1 3R1040TA G1 4R810TA G1 4K1080TA G2 6K1080TA G2 6SL1500TA G2 6SL1500TA G3 18 Engine DV8TA G1 DV8TA G2 DV10TA G1 DV12TA G1 DV12TA G2 Note Recommended K Oil Premium Filters Change Interval First Service and Oil change within 50 hours or 30days from date of commissioning whichever is earlier G1 Check G2 Check within 500 hours or 7 months from date of commissioning whichever is earlier G3 Check within 1000 hours or 13 months from date of commissioning whichever is earlier G4 Check within 1500 hours or 19 months from date of commissioning whichever is earlier After first service Oil change period is 500 hours or 6 months whichever is earlier If SDG Set kept ideal not in operation for 6 months or more without preservation than revalidation must be carried out and customer has to bear revalidation cost JAKSON amp CO JAKSON amp CO Air cleaner mounting Air cleaner cleanliness Air cleaner clamps Hoses Grade amp specs of oil used Lub oil level amp positioning of oil filter Check lub oil safety All Nuts amp Bolts Battery condition Battery Terminal Leans Electrolyte level Fuel Filter V Bel
20. aler Engine overloading Ensure Load as per rating or manufacturer recommendation Prolonged oil change period Contact to KOEL Service Dealer Engine needs overhauling Contact to KOEL Service Dealer EZEEREEELEEEREREEEEEIERREELEEXEKERREKEEERERREELEEREKREEEEEREEEEEIEERERIEEERERREEKERREREEEIEEREEEREEXEEREREEEEEIERRERLEIEEKEREEEEEIEERERREEEREREEEKEEIEREEEREKERA JAKSON amp CO Faulty fuel Pump Contact to KOEL Service Dealer Incorret valve amp fuel timing Contact to KOEL Service Dealer Loose component Check and ensure all component should be tighten Component fouling with any othe
21. ange the lube oil as per KOEL specification Engine overheat Dirt choked suction tube strainer Clean the tube strainer Clogged oil passage Check and clear oil passage Contact to KEOL service dealer Top up with K Cool super plus Engine overloading Ensure Load as per rating or manufacturer recommendation Change the lube oil as per KOEL specification Ende went Vend JAKSON amp CO
22. chever is earlier This warranty will only be applicable if customer source the filters K oil premium K Cool super plus and avail the services from the Kirloskar Oil Engines Ltd Authorized Service Dealer This warranty is not a free service Contract Date 08 14 For JAKSON amp COMPANY Note 1 This warranty certificate is only applicable for supplies in India 2 Warranty is applicable as per Kirloskar Oil Engines Ltd guidelines and Kirloskar warranty card can supersede this warranty certificate 3 Use Battery within one month from the date of Invoice and follow all the guidelines for upkeepment of battery otherwise repairing recharging replacement under warranty will not be applicable All charges pertaining to recharging of deep discharge battery will be to customer account After commissioning of SDG set responsibility of attending complaints under warranty and otherwise is of Authorized Kirloskar Area Service Dealer JAKSON amp CO o xX c lt ra E O z JAKSON amp CO
23. e medium VV ON ON Always switch off the charger first before disconnecting the battery from the DG set Never put tools etc on the battery v v Remove battery terminal Positive and Negative during any welding work on genset Ww wi W N wl wi A W wl im i Ww i W N ul W i NN NN wu i Ww wi W N ul iN W Nu wl NN IQ N W wi Wl wj IQ N M A W NN IQ N W wi i i ul N W i Wl NN N W W W W ul iN i NN NN IQ N wl i NN IQ N W NN IQ wi i wi ul i Wl NN wl W i W wj IQ wi wi M NN wl wi iN wl wl wi wi W wl ul N W i W N i N W wi W wj I N Wl NN Ww wi Nu wl wl wi wi W wl wl wi wi W WI ul N W wi W wj ul N M wi NN NN wi m wi m wi wi W wl wl W i Wi WI i N wi wi W NN N wl NN wi i wi m Ww wi W N wl i wi NN NN wl ul N S W EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEECEEEEEEEEEEECEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEECEEEEEEEEEEEEEELEEEEEEEEECEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEEREEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEZEEZEEEEEEEEEEEEEE
24. ed is low Adjust prime mover speed to rated speed EE aidan V Trim pot incorrectly set voltage by V Trim pot in AVR Y Voltage High terminals of the AVR Check and correct Incorrect voltage setting Adjust voltage by V Trim pot in AVR AVR Defective Replace AVR Speed fluctuation of the prime mover Set the speed of the prime mover Incorrect setting of stability pot Adjust stability pot in AVR Leading load power factor Correct the power factor Load hunting fluctuates Check and reduce the nonlinear load rapidly High percentage of non linear Rectification Correct percentage of load non linear load Voltage fluctutation JAKSON amp CO line with name plate rating Blocking of ventilation passage necessa Over loadinz of Generator Low speed on load Adjust prime mover speed 8 Low load power factor Reduce the load Generator operating at very Check voltage and adjust high voltage High percentage of non linear Check and reduce the nonlinear load load Excessive vibration and noise Coupling and foundation Tighten the bolts bolts loose Bearing defective Set prime mover speed Prime mover speed droop properly Droop Governor improperly set characteristic of engi Generator does not share KW load proportionately Quadrature droop incorrect Set quadrature droop correctly by Generator does not share QDC Pot in AVR KVAR load proportionately QDC CT Polarity reversed Interchange CT seconda QDC CT are not in
25. ify that Jakson amp Company Diesel Gen Set Sr No eee is warranted to be free from inherent manufacturing defects under normal use and Preventive maintenance The Silent GenSet will be repaired free of cost if it is go out of order due to inherent manufacturing defect of components as per schedule given below Engine Alternator warranty 2 years from the date of Invoice or 5000 Hours of operation whichever is earlier Acoustic Enclosure 12 months from the date of invoice Control Panel Control Panel Parts amp Battery 12 months or 3600 hours of operation from the date of commissioning or 13 months from the date of invoice whichever is earlier Safety system wiring harness rubber components of engine rubber sealing of canopy hinges and lock 12 months from the date of commissioning or 13 months from the date of invoice whichever is earlier The warranty is subject to condition that no alteration addition or repair is done or attempted to be done The warranty does not cover Normal Wear amp Tear of the Components of Silent Gen Set Any type of damages during handling or improper storage installation amp improper maintenance If K Oil premium and K Cool Super Plus engine coolant is not used If first service check has not been carried out through Authorized Service Dealer within seven days of installation followed by second service check within 250 hrs or 3months from the date of first service check whi
26. ing removed If any fault is traced Do not attempt to start the genset unless fault is rectified Do not use start push button continously for more than 5 seconds Do not check lub oil coolant level while DG set is running Do not change or modify any wiring it may cause void of warranty Do not turn off the fuel supply for stopping the genset unless any emergency Do not start genset on load Do not allow the genset to run idle for Long periods on no load Do not leave behind tools waste cloth loose wires etc after repair or maintenance work is completed near the genset If the DG set is with AMF panel do not tuch live wire as Main supply is available in circuit from AMF panel even if DG set is OFF Do not get the DG set repaired and serviced by any unauthorized person It may cause void of warranty Do not add acid of any strength to the Battery for topping up use distilled water only Do not attempt to open the locked doors it can cause failure of door lock Y Y Y VY VVVVVVVVVNV JAKSON amp CO i5 TROUBLE SHOOTING ENGINE Important No
27. ne speed does not remain constant Engin dos not reach governed speed Engine overloading Ensure Load as per rating or manufacturer recommendation JAKSON amp CO 123235153 33234543232343233343333223323233433232333233331333323333233323233322323333333333333333372333323 332373332333 0323332333323 33323333323 3334023333 9333223 4322333 9333333493332 9322333303223 3334023323 933323 332333 3333324233323 332323 332333323327 D ETT nea any modification in air inlet arrangement Dirt Dirt clogggedaircleaner ged air cleaner_ Clean air cleaner air cleaner Change the fuel and use good quality fuel Engine overloading Ensure Load as per rating or manufacturer Excessive smoke at full load recommendation Contact to KOEL Service Dealer Dust entry in air inlet system Make necessary arrangement to stop dust entry without any modification in air inlet arrangement ar not proper recirculation inside canop Dirt clogged air cleaner High exhaust back pressure manufacturer recommendation Contact to manufacturer Faulty fuel Pump Contact to KOEL Service Dealer Wrong grade of lube oil used Ch
28. o install the DG set in an open area No shade roof is required over it However if the AMF Panel is outside the Acoustic Enclosure then a shelter is recommended for the AMF Panel For Roof Top Installation ensure that the civil structure is capable to bear the static and dynamic load of DG set Theload ofthe Silent DG set should be borne by Columns and Beams ofthe building Proper space should be there for Earthing If there are no space constraints the DG set should be placed near the distribution panel The DG set should be located away from polluted surroundings such as corrosive fumes cement dust fibres cotton and toxic chemicals to avoid overheating ofthe D G Set There should be sufficient space around the Genset to avoid resonance and echo effect which contributes to abnormal sound from Genset The space should be open without any obstacles
29. orrect the problem 9 Ifthe MAINS supply is available set the battery charger to boost and wait till the battery voltage is 12 24V Refer KG controller manual for further trouble shooting related to KG controller JAKSON amp CO Enginestarts butthere is no Voltage from the control Panel Check HRC fuses MCB below the DG MAINS contactor MCB should be in ON position and fuse should be OK Check the setting of AVM Alternator Voltage Monitor Check the overload relay ifit is tripped than press the reset lever Check power cable connection from Alternator to control panel gt The Main supply is restored but the load does not transfer Check the control MCBs these should be in ON position Check if all three phases RY YB and BR of Mains supply are available All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay KG Controller If required lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays KG Controller Increase the voltage setting gradually if Mains Voltage is not acceptable on load equipment Distance of panel from DG set should not be more than 5 meters Check wiring connection of MAINS contactor Supply to contactor coil should be available JAKSON amp CO JAKSON amp CO JAKSON amp COMPANY BY KIRLOSKAR WARRANTY CERTIFICATE FOR SILENT GENSETS This is to cert
30. r Check and ensure all component should fitted component proper AVM AVM pad broken or wrong fitment broken or Wrong fitment Replace if AVM Pad broken ie foundation level is not proper Excessive Vibration Contact to manufacturer or KOEL Service Dealer Engine rotates very Engine seized Contact to KOEL Service Dealer Poor quality of fuel Change the fuel and use good quality fuel Diesel knocking slowly during starting Contact to manufacturer or KOEL Service Dealer Check and ensure proper use of Canopy Lamp Loose or dislodged wiring Check wiring it should be as per drawing and Tightened JAKSON amp CO TROUBLE SHOOTING ALTERNATOR Decfective voltmeter Check voltmeter and replace Short circuit between phases Check and ensure no short circuit between phases Neutral earthing short with body earthing Check and rectify Power cable faul Cehck and replace Excitation circuit open Check for loose connection Incorrect excitation circuit Check for proper connection connection Check for residual voltage If residual No voltage from Alternator voltage is less than 2 5V L N field flashing required for few seconds Field fleshing procedure 1 Disconnect regulator connections 2 Connect 12 24V battery keeping F1 to positive and F2 to negative terminal of excitor stator Low residual voltage Rotating diode faulty Pars Rise diodes and replace DIEN Prime mover spe
31. t for charging alternator V Belt tension Coolant level in the Radiator Check coolant temp safety Wiring Engine Panel Check all wires tightening Alternator back cover Cable termination Canopy door alignment Canopy door hinge operation Fitted Not fitted Clean dirty replaced Dry or oil type Cracked normal not clamped tightened 15W40 as per koel manufacture s recommendation OK Not OK OK Not OK Proper Tightened Charged Discharged Proper damaged replaced High Medium Low Proper to be replaced Proper Tightened not Proper Proper adjusted High Medium Low filled OK not OK OK not OK OK not OK Fitted removed Proper loose Tightened proper adjusted not proper OK not OK Adjusted 9 JAKSON amp COMPANY LEZELEEIEEEEEEEEEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEREEEEEEEEEEEEEEEEEEEEEEZEEEEEEEEEEEEEEEEEEEEEEEEEEEEELEEEEELEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEREZEEEEEEEEEEEEEZEEEEEZEEEEEEEEEEELEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEFEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEZEEEEEEZEEEEEEEEEEEEEEEEEEEEEEEEEEEEZ Routine Maintenance of SDG Set In Running Hours 1st i 50 3 3 es NM LL DX x Check Adjust Change Clean UEZEEEEEEEEEEEEEEEEEEEEEEEEEEREEREEEEEEEEEEEEEEEEEEEEEEEEEEEEEELEEEEEZEEEEEZEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEREEEEEEEEEEEEEEEEEEEEEEEELEEEEEELEEEEEEEEREEEEEEEEEEEEE
32. te Trouble shooting points are given just for reference Please do contact KOEL service dealer for any check or repair Dirty clogged air cleaner Check Vaccum indicator if red ribbon is visible then Clean air cleaner refer manual for cleaning Dirty or choked fuel filter Contact to KOEL Service Dealer Engine does not Faulty fuel Pump Contact to KOEL Service Dealer start Faulty starter Contact to KOEL Service Dealer Engine used after a long time Check and Charge battery or Contact to KOEL Service dealer Battery discharged Charge the Batte Loose or dislodged wiring Check wiring it should be as per drawing andTightened Engine fails to start Check wiring it should be as per drawing andTightened Check Vaccum indicator if red ribbon is visible then Clean air cleaner refer manual for cleaning Change the fuel and use good quality fuel Air in Fuel line Vm Dirty or choked fuel filter Contact to KOEL Service Dealer B Faulty fuel Pump Contact to KOEL Service Dealer time Water mixed with fuel Check the reason and sort out or Contact to manufacturer KOEL service dealer Contact to KOEL Service Dealer Engine needs overhauling Contact to KOEL Service Dealer without any modification in air inlet arrangement Clean air cleaner refer manual for cleaning Engine not taking High exhaust back pressure Check Exhaust pipe arrangement it should be as per load manufacturer recommendation Contact to manufacturer Derating due to
33. tended beyond the canopy Fuel pipe line job is completed if Fuel Tank is outside the canopy If DG set installed inside a room a duct to be provide for fresh air amp hot air exit should be 1 5 times higher then the canopy inlet amp outlet Power cable laying fitting and connection jobs are completed with proper glanding If panel is out side canopy Power Cable Control cable laying fitting amp connection jobs have been completed Mostimportant Battery is charged If the DG set is with AMF Panel then 230 V AC mains or 415 V AC mains R Y B N supply isprovidedatthe AMF Panel to check its operation and for Battery Charger Dieselis available in the Diesel Tank Engine is duly filled with Lube Oil upto H mark Coolant level is up to H mark Load is available Note Itis mandatory to get your Diesel Generating Sets commissioned on load and kindly do sign the commissioning report made by our Service Engineer JAKSON amp CO ROUTINE CHECK POINTS JAKSON amp CO Check Fuel Level Drain water from fuel Tank Especially during winter Season Check Coolant level in the Radiator Check for any leakage Check for any loose connections Check Battery condition Check Lube oil level and quality lube oil should not be very thick with visible carbon and metal particles Check fuel coolant lube oil level Check for any leakage Check electrolyte level in Battery It should be between
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