All generating sets General considerations
Contents
1. 33 4 WM AGG uuu u uu aa u nu 33 42 Check pelore E 34 4 5 Diivi E LOI 34 4 4 Unhitehing the Irailep ll c H 34 4 5 Implementation for ins Allan m 34 33522903401 ind3 2 52 YSDMO 5 Installation of electrical generating sets in containers 35 5 1 Handling transport and positioning of the containers 35 SL Q e da da ee a dodo de 35 ______ 37 5 1 3 Installation positioning cccccccssssssssssseseseseeseeseseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 38 5 2 AVIAN CW ANCE uu PRU 40 6 Preparation before operating the set 40 diio CP 40 0 2 onnet c her AA 40 0 3 Starline Sl uuu xl iii Ea a EEE e a a dissout 40 6 4 Load 16 tUoninstaliloniu uu uuu 40 zBut2. QN TWD 740 29 29 COOLING EX II 390 390 390 390 Si ele TAD 1630 1631 COVER M 228 x x COVER x x 229 500 500 8 3 Circuit capacities Mitsubishi engines in litres SAL2 SD serie SL S12R s rie SR S16R s rie SR L3 SD serie L L3 SDH serie L CIRCUIT AND TANK CAPACITY S3L2 SD serie SL S3L2 SDH serie SL S4L2 SDH serie SL S4Q2 serie SQ LUBRICATION nan 4 in litres COOLING 7 in litres i FUEL in litres 33522903401 ind3 44 52 Feil 8 4 Circuit capacities John Deere engines SS E m E x N SI 6068 2150 187kW 1800 rpm 6068 2120 153kW 1500 rpm 6068 2 160 183 1500 rpm CIRCUIT AND TANK CAPACITY 6068TF250 4045TF250 LUBRICATION 1n litres LA NO 13 5 13 5 13 5 13 5 13 5 13 5 3 E 3029TF150 COOLING 1n litres EXII 100 COVER M 128 COVER M 129 ml u ii UT 20 2 20 2 23 6 23 6 23 6 23 6 25 6 27 3 340 0 16 1 16 1 18 9 18 9 21 3 229 BOETE HORS oom HR HR CORE TOORE TOORE a S L OO LA LA 00 100 100 100 1 180 1 180 OO in litres espe m E To E COVER COVER 33522903401 ind3 45 52 JY
3. 9 3 1 Description Vent pressure equalising line for an engine working with pressure in the sump other than atmospheric pressure Oil intake to the regulator a 1 2 pierced inlet port is located on each side of the lower section of the regulator Outlet ports a 1 2 pierced outlet port 15 located on each side of the of the regulator chamber NN nim mL m SP ms Centre of the regulator and level maintenance line E s L So m Regulator inlet Regulator outlet Diagram 9 2 Oil level gauge 33522903401 ind3 52 52
4. EYSDMO Frost The draining bolt is inefficient and the Japy pump has not been supplied by it for a long time except for special requests using the control On the other hand it is indispensable if the pump is exposed to frost to use a small draining tap on the suction pipes about 0 75m above the pump In any case the pipes must be fitted with a foot valve This device is necessary for draining the pump If there 15 a threat of frost do not forget to open this tap while checking that the discharge port 1s free to let air in Draining should take place normally but for increased safety after the water has flowed out pull the lever two or three times to complete the draining If the body or cover is cracked by frost do not try to repair it by autogenous welding as this would distort the part Extended lack of use If the pump is not used for a while it is recommended if frost is not likely to check that the pump chamber 15 always full of pumped fluid if frost 1s likely to drain and if possible pull the lever a few times to prevent the internal components from becoming blocked by oxidation if not drain and add liquid paraffin by spraying if possible to prevent oxidation and the internal components from becoming blocked In the event of oxidation and blocking never force the lever as this risks breaking the piston Remove the cover carefully clean the inside of the pump with an oiled cloth but never with abrasive m
5. 123456 MotorNr 526 100 950 CD4045TF150 08 X XX DEERE amp COMPANY MOLINE ILLINOIS MADE IN FRANCE Baujahr RG7935 UN 13NOV97 Masse MTU Motoren und Turbinen Union Friedrichshafen GmbH VOLVO PENTA jENGINE MODEL gt SPEC NO FRIEDRICHSHAFEN Dieselmotor SERIAL Meme deum W RATED NET POWER without fan kW hp XXX XXX Drehzal with fan kW hp XXX XXX ISPEED AT RATED POWER rpm MTU Motoren und Turbinen Union Friedrichshafen GmbH l gt PRELIFT mm INJ TIMING X X X X XXxX X MADE IN SWEDEN 3826077 Engines Diagram 1 2 Examples of identification plates 33522903401 ind3 14 52 gt sen EU o ALTERNATEURS PA 3 ALTERNATORS LSA i En Date E PUISSANCE RATING e ECH us Im me 20 v 3 LACS LACET Tc fre m Is 3 BS 5000 PART 3 IEC 34 1 seem ws It jou Le 9 a E 150 8528 3 Say 132 vr Yus ie Term ES w n THE TRE T Alternator Designation ARMOIRE DE 400K VA A0217010 Cde AVP31650 01C Reference SOREEL 371562 03 No OF 02280753 Cabinet Diagram 1 3 Examples of identification plates 33522903401 ind3 15 52 SDMO 2 INSTALLATION It is recommended that you use a professional to ensure correct installation and start up The company cannot be held responsible for breakdowns related to the conditions of installation Sectio
6. 52 9 3 REN RAB automatic oil auxiliary adjuster 52 D a D a susisnuu 52 Attached documents User manual for the control unit if fitted level A Wiring diagrams supplied with the reference material or with the electrical generating set Level A User and maintenance manual for the engine level A User and maintenance manual and spare parts catalogue for the alternator level A Engine spare parts catalogue level B Workshop manual repair for the engine level C 33522903401 ind3 3 52 YSDMO 1 PREAMBLE 1 1 Introduction 1 1 1 General recommendations Thank you for choosing an electrical generating set from our company This manual has been designed to help you operate and maintain your electrical generating set correctly The information contained in this manual is taken from technical data available at the time of print In the intention of permanently improving the quality of our products this information may be amended without warning We are interested in your comments This manual is updated regularly We are interested in your comments and suggestions as they enable this document to be made increasingly more useful You can contact us with any comments or suggestions at fax technical documentation department number 00 33 0 2 98 41 16 12 by e mail doctech sdmo com Read the
7. On site type trailer These trailers are not fitted with a main brake and so cannot brake when operating the tyres are designed for a speed of 17 mph 27 Km h Therefore it is absolutely forbidden to exceed this speed Road type trailer The driving speed should be adapted to road conditions and the trailer handling Driving at sustained speed causes tyres to heat up therefore it 1s important to stop from time to time to check them Excessive heating can lead to a blow out and hence a serious accident When reversing do not forget to lock the overrun brake Particular attention must be paid to wheel torquing on new vehicles Indeed during the first few miles heat build ups on the wheel hubs and brake drums lead to reduced wheel torquing It is therefore essential to check the torquing every 6 miles 10 Warning Waming kilometres until no further loosening is noted The torque test should nevertheless be carried out before towing 4 4 Unhitching the trailer This operation should be carried out on horizontal flat stable ground lock the wheels lower the front wheel disconnect the road signals wire refit the hitch using the wheel to release the hook ring from the tow vehicle release the tow vehicle engage the handbrake 4 5 Implementation for installation Procedures to be carried out check that the ground is strong enough for the assembly not to sink into it using the front wheel
8. d Safety guidelines The generating set must be earthed To do this use a minimum 25 mm stripped copper wire and 16 mm insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground The earthing rod resistance value should correspond to the values shown in the table below Note use the highest differential setting from the installation as a guideline R Ul I An The resistance value is calculated in the following way Maximum resistance value of the earth socket according to the differential unit operational current operation time should not be longer than 1 s I An differential The UI value 25 V 15 required for site installations and rearing pens etc 2 3 2 12 Cooling Three types of heat production must be dissipated heat from the engine cooling circuit s heat radiating from the engine and exhaust ventilation air from the room exhaust gases The systems described below evacuate and pipe the heat produced by the engine cooling circuit a Ventilated radiator The engine cooling circuit is connected to a tubular ribbed radiator at the end of the frame in order to implement this procedure This radiator 15 cooled by the fan controlled directly by the engine In all cases the air 1s blown in the direction from fan radiator Cooling is ensured by the circulation of air across the room An expansion vase can compensate f
9. efficiency absorbent material protected by a perforated metal sheet Absorbent reactive silencer The gas enters an expansion chamber lined with absorbent material supported by perforated metal sheets then into an absorbent sound proof duct Diagram 2 24 Absorbent reactive silencer 2 3 2 11 Electricity a Connections general information In the same way as for low voltage electrical installations running and maintenance are subject to NF C 15 100 standard rules or the standards of the relevant country They also comply with NF C 15 401 standard rules or the standards of the relevant country b Power cables These can be unipolar or multipolar according to the power of the generating set Power cables should preferably be installed in ducts or on a cable tray for this purpose c Battery cables Install the battery or batteries immediately beside the electric starter motor The wires will be connected directly from the battery terminals to the starter motor terminals The first instruction to follow is to check that the polarities of battery and starter motor correspond Never swap the positive and negative battery terminals when connecting them This could cause severe damage to the electrical equipment The minimum section of the wires is 70 mm It varies according to the power of the starter motor but also the distance between the batteries and the set voltage drops on the line 33522903401 ind3 29 52 YSDMO
10. position the set as horizontally as possible engage the handbrake lower the rear trailer supports and lock them 33522903401 ind3 34 52 EYSDMO 5 INSTALLATION OF ELECTRICAL GENERATING SETS IN CONTAINERS When the generating set is working in automatic start mode the air evacuation doors must be open When the generating set is working in manual start mode the air evacuation doors must be open before it starts When the generating set has been started and the doors have remained closed they are formally prohibited from being opened very severe risk of injury owing to sudden opening of doors Before beginning handling procedures you must ensure that the operating personnel has the necessary qualifications All handling procedures must be carried out under the instruction of one co ordinator only It is essential to use an adapted lifting vehicle lifting and travel limit etc fitted with a lifting beam to ensure that the container 15 moved correctly 5 1 Handling transport and positioning of the containers 5 1 1 Handling instructions attach the lifting vehicle slings to the handling rings on the container carefully stretch the slings without lifting the container check that the sling hooks are correctly attached and the equipment 15 solid lift the container carefully and without jerking direct and stabilise the container towards its final position position the container while still lifted
11. safety instructions carefully in order to prevent any accident incident or damage These instructions must always be followed You are likely to encounter several warning symbols in this manual This symbol indicates a definite risk to the health and life of people Not following this instruction may seriously affect the health of people or prove fatal This symbol draws attention to the potential risk to the health and life of people Not following this instruction may seriously affect the health of people or prove fatal This symbol indicates a dangerous situation if the warning is not heeded Not following this instruction could result in non serious injury or damage In order to obtain optimum efficiency and the longest possible life for the electrical generating sets maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all adjustments and repairs are carried out by personnel who have received the appropriate training The dealers are suitably qualified and can answer all of your questions They can also supply you with spare parts and other services 33522903401 ind3 4 52 YSDMO The left and right sides can be seen from the back of the electrical generating set the radiator 1s at the front Our electrical generat
12. trailer container holder etc should be suitable for this use and provide all safety guarantees in terms of its capacity to support the load and the attachment devices Driving should be on vehicular roads of sufficient quality not to damage the equipment stored inside the container Although they look very like ISO transport containers our equipment does not comply with the different certification tests that these have undergone Therefore our containers cannot carry additional loads no stacking 33522903401 ind3 37 52 5 1 3 Installation positioning The position should first be considered in relation to the electricity distribution centre fuel storage the general environment and type of ground before the equipment can be accommodated The installation area should be flat enough for the frame to rest level on it and strong enough so that the container does not sink down If the container s are being installed definitively a concrete foundation must be constructed for which the calculations and execution must be performed by a specialist z fee gan de dh e EH d YES Diagram 5 4 Positioning containers 33522903401 ind3 38 52 YSDMO The environmental impact should also be analysed so that the disturbances to be caused by the equipment will not affect those living close by Therefore it is essential to be aware of the regulations in force in
13. while it 1s working or just after it stops wait until the motor cools down Do not touch hot components such as the exhaust pipe and do not put combustible material on them Keep all flammable or explosive products petrol oil cloth etc well away when the set is running 33522903401 ind3 10 52 YSDMO Good ventilation is required for your generating set to work properly Without ventilation the engine will quickly reach an excessive temperature that could lead to accidents or damage to the equipment and surrounding items Do not take off the radiator cap when the engine is hot and the coolant is pressurised due to risk of burns Depressurise the air oil and coolant circuits before removing or disconnecting any unions ducts or connected components Be aware of any possible pressure that might be present when disconnecting a device from a pressurised system Do not look for pressure leaks manually High pressure oil can cause physical accidents Some preservative oils are flammable Also some are dangerous to inhale Check that ventilation is good Use a protective mask Hot oil causes burns Avoid contact with hot oil Check that the system is no longer pressurised before carrying out any procedures Never start or run the engine when the oil filling cap is off as oil may be ejected Never start or run the engine when the oil filling cap is off as oil may be ejected Never cover the generating set with a fine l
14. 3 50 52 EYSDMO 9 2 2 Electrical data power 0 37 kW engine made for continuous work 10 658 single phase 50 Hz 220V 2 4 A 240V 2 1 A 10 658 single phase 60 Hz 208V 3 7 277 3 3 A 11 661 three phase 50 Hz 380V 0 8A 415V I A JEV 11 661 three phase 50 Hz 200V 1 5 240 1 6 11 661 three phase 60 Hz 380V 0 9 480V 1 4 A 11 661 three phase 50 Hz 208V 1 8 240V 2 A The engines are not flame proof Do not use them in locations where there may be flammable vapours 9 2 3 Suitable fluids water fuel diesel amp light oil maximum viscosity of 10 cst at atmospheric temperature 9 2 4 Prohibited fluids Fluids Fire explosion Supply fluids Corrosive chemical fluids solvents Damage to linings and joints 9 2 5 Maintenance The pumps do not require any specific maintenance Possible checking for leaks at the joints 33522903401 ind3 51 52 50 9 2 6 Faults and repairs The engine does not work Possible causes Actions No electric current Look for a possible foreign body No flow or insufficient pressure Possible causes Actions Suction height too high Move the pump nearer to the fluid to be pumped Airinthesuction pipes Check that they are sealed Fluid leak Check the pipe connections Replace the seals 9 3 REN RAB automatic oil auxiliary adjuster
15. EYSDMO Users guide and maintenance manual All generating sets General considerations Safety instructions Installation R f constructeur MUE SD A R f GPAO 33522903401 ind3 YSDMO CONTENTS 1 Preamble M IET 4 cd 4 eege 4 1 1 2 Structure of the reference materlal 5 D 5 iMi E E 6 o 6 L2 Pictoserams and their 7 1 3 Safety instructions and reeulations 8 TEE 8 1 3 2 Risks related to feed gas concerns gas sets eee 9 1 3 3 Risks related to exhaust gases and fuels 9 E34 Risks related 10 toxic Products 10 Kee or fire 10 1 3 6 Risks related Gleewegen 11 1 3 7 Dangers presented by electric currents first 12 1 3 8 Risks related to moving the set eee 12 1 3 9 Recommendation for the operator and environment 12 lot tili i SOUS a ices E TL UT E E umu ns 14 VENIS T ea uu TUR 16 2 MN O
16. L LOUE LE in uuu TI 16 2 1 SAR durno vnloadiN i nes cames ee on ner one eo ee 16 2 12 Example WSCC uuu u uuu tectae tied estan das ne as ann tee tes ee ee 16 2 EE eege ee E 16 AE PA MUN 16 GE re UDC NEN cm 17 2 2 US CEC u uuu u a C T EL NEM 17 2 3 Installation OF TIXCC SOUS Eea Na 19 SAN sa 20 2 32 1 NAY pu II L u EEE ___ gt _ ___ __8 20 pL sd UM ee CR 20 21 2 COS Te 21 U E 21 EE 22 PAS M IIR a maan assaa a usa aauasn 22 O 22 PA Hilli METTRE 23 pw 24 2 3 2 10 Burnt gas TERT 25 E GN ri eree mm 29 pa COCONINO EA 30 2 3 2 13 Special 31 3 Installation of mobile site sets 32 3 1 General EEE 32 EE ENEE ENEE HEEN 32
17. LOOR PLATE Diagram 2 6 Example of a generating set site 33522903401 ind3 19 52 YSDMO 2 3 1 Position It should be determined on the basis of use There are no specific rules governing the choice of location other than proximity to the electric distribution panel and disturbances caused by the noise However fuel supply burnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered Ground too uneven or soft Reduced access Set incorrectly positioned Fuel filling impossible Opening Semer doors impossible Diagram 2 7 Examples of problems that may be encountered 2 3 2 Measurements and layout These are governed by two types of requirement 2 3 2 1 Static requirements These are the dimensions of the equipment installed and its surroundings namely daily service fuel tank cabinet silencer batteries etc 33522903401 ind3 20 52 SDMO 2 3 2 2 Dynamic requirements These are the measurements to be adhered to between each piece of equipment to allow for refitting and possible removal About a 1 metre space around the set is considered the minimum required for carrying out problem free maintenance This will give enough space to check that the doors of covered sets open fully that equipment can be accessed for maintenance and that integ
18. RIATION ABOVE 50 g l BETWEEN ELECTROLYTE RECHARGE THE DENSITY TEST BATTERY FULLY gt 1 22 kg l CARRY OUT QUICK ELECTRICAL PERFORMANCE TESTS step 3 gt 1 22 kg l ee gt STEP 2 IN qww W lt S scwatcsuaOnM l CHECK THE A POSITIVE RESULT g3 R TEST OF BATTERY USING A QUICK MIDTRONICS WEGA ELECTRICAL OR SIMILAR TYPE PERFORMANCES OF TESTER THE TESTER GIVES A NEGATIVE BATTERY RESULT STEP 3 33522903401 ind3 42 52 50 8 FUEL AND CONSUMABLES The capacities stated in this section apply to standard generating sets All specifications product features are given in the motor and alternator maintenance manuals attached to this manual In addition we recommend the consumables to be used in the specifications section 8 1 Sp cifications 8 1 1 Oil Grades Motor Make Type Make Type SDMO GENLUB TDX 15W40 John Deere All John Deere PLUS 50 GENLUB TDX 15W40 MTU Mitsubishi SDMO GENLUB TDX 15W40 Perkins Fuel GENLUB TDX 15W40 as MOBIL PEGASUS 705 All SDMO GENLUB TDX 15W40 8 1 2 Specifications of coolants Motor Make Type Make Type Tous SDMO GENCOOL PC 26 C Tous GENCOOL PC 26 C Tous GENCOOL PC 26 C Tous LL GENCOOL PC 26 C Tous GENCOOL PC 26 C Tous GENCOOL PC 26 C 33522903401 ind3 43 52 YSDMO 8 2 Circuit capacities Volvo engines CIRCUIT AND TANK CAPACITY LUBRICATION in litres gt
19. SDM0 8 5 Circuit capacities MTU engines 12V2000G43 12V2000G83 16V2000G83 12V2000G63E 12V2000G63F CIRCUIT AND TANK CAPACITY LUBRICATION 82 82 82 82 110 110 110 130 260 260 260 290 1n litres d 180 180 212 180 212 261 261 261 268 200 200 200 215 215 1n litres 12V2000G23E ak 12V2000G23F ISO20 FUEL CIR 20 2347 2947 2347 2347 2347 2347 2947 2947 3 in litres 15040 fi 500 500 NO LA I Ix I 500 500 500 500 3000 3000 3000 3000 33522903401 ind3 46 52 YSDMO 8 6 Circuit capacities engines Nevada GMC GMC GMC GMC GMC GMC CIRCUIT 430 643 857 874 T 881 881 T AND TANK CAPACITY LUBRICATION 1n litres COOLING 1n litres 8 6 Circuit capacities Perkins engines ENGINES 3012 4012 TAG TAG CIRCUIT AND TANK CAPACITY LUBRICATION 1n litres 122 7 in litres K 2 TAG2 a FUEL in litres 33522903401 ind3 47 52 YSDMO 9 MAINTENANCE OF OPTIONAL EQUIPMENT 9 1 Japy pumps for clear fluids 9 1 1 Technical specifications Base block Zamak piston seat and valves Diesel and petrol Steel shaft against mounting clamps and lugs O ring Base block Hydrocarbons Brass piston seat and valves Max viscosity 300 cst Steel shaft against mounting clamps and lugs O ring Pump body Cover Lever Piston Seat Lever nut O r
20. SDMO 2 3 2 5 Openings The room should include a certain number of openings which are required for it to operate a door giving access to the generating set and its accessories preferably in line with the set s floor plate ventilation openings fresh air inlet and hot air outlet located so that scavenging takes place in the direction from the alternator towards the engine Their surfaces depend on the power of the generating set being installed general atmospheric conditions the cooling system selected and the soundproofing procedure 2 3 2 6 Lifting The lifting system should usually be an integral part of the construction It is made up of an H or I steel rail embedded in the walls and ceiling and a crab It should be easy to handle and is generally used on top along the longitudinal axis of the set and directed towards the exit Diagram 2 9 Example of a lifting system 2 3 2 7 Soundproofing The room is soundproofed using two procedures Insulation This prevents the noise from crossing the walls and in this case it is the weight then thickness of the wall that is important Absorption These are materials that absorb sound energy and this procedure will be used on ventilation openings As aresult of this the air inlet and outlet sections are increased The internal lining of the room can also be covered with absorbent material designed to lower the sound level in the room and consequently through the walls ventil
21. aterial Lightly oil before refitting The Japy pump does not normally require any lubrication After several years of service or after use for water or fluids that are full of impurities or slightly acidic it becomes necessary to replace the main internal components This procedure must be carried out by a mechanic In general when pistons and seats need to be replaced we recommend a standard replacement pump To remove the lid and to check inside begin by unscrewing the 6 bolts that attach the lid to the chamber Then to undo the lid hit it preferably with a piece of wood alternately on the discharge and suction manifolds while keeping the other hand on the piston rod and the valve gland clamp Do not carry out these removal procedures often Before refitting carefully clean the whole of the inside with a cloth lightly lubricate the internal parts of the chamber with liquid paraffin put the piston back in place by pushing down slowly with a semicircular motion Check that the suction seat 1s held in place and that the felt pad is properly positioned Put the bolts back in position retighten the blocks moderately and alternately until the cover 1s locked down 9 2 Japy pump kit 9 2 Technical data max flow 37 L man max pressure 2 2 bars with water rotation speed 2800 rpm max suction height 6 m fitted with a by pass operation with discharge cut off 2 to 3 1ns Mx PI 55 protection 33522903401 ind
22. ation openings and door 33522903401 ind3 22 52 SDMO General arrangements building structure made from framing concrete or solid concrete blocks 20 cm thick minimum anti vibrating floor plate under the generating set when adjoining sensitive areas ceiling and walls covered if necessary with absorbent materials choice of adapted exhaust silencer s soundproofed door for access to the room and if required to the pressure lock for a very low sound level sound traps fitted to the air inlet and outlet sleeves Sound trap silencer Sound trap Soundproofed doors Diagram 2 10 Example of an installation 2 3 2 8 Ventilation A heat engine generates a certain amount of heat which must be evacuated outside the room to ensure the set works properly The heat released by the set originate from different sources cylinder cooling radiation from the engine unit and exhaust duct alternator cooling Also the room must be fitted with air inlet and outlet openings suitable for the conditions of use and cooling system As you know insufficient ventilation will cause the atmospheric temperature to rise and lead to problems ranging from at least a loss of engine power to the set stopping altogether Air must flow through set room from alternator gt engine gt radiator This solution also supplies the quantity of fresh air needed for combustion The openings should be of ample size Air intake and
23. ayer of oil for anti rust protection Never fill up the oil or coolant when the generating set is running or when the engine 15 hot 1 3 6 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15 100 or the standards of the relevant countries Read the manufacturer s identification plate carefully The values for voltage power current and frequency are shown Check that these values match the supply use Never accidentally touch naked wires or disconnected connections Never handle a generating set with wet hands or feet Maintain electrical wires and connections in good condition Using equipment in poor condition can lead to electrocution and damage to equipment Operations should only be carried out on the generating set when the installation or the equipment is switched off Electrical connections must be made in accordance with current standards and regulations in the country Do not use faulty poorly insulated or provisionally connected wires Do not invert the positive and negative terminals of batteries when connecting them Such an inversion can lead to severe damage to the electrical equipment Follow the wiring diagram supplied by the manufacturer The generating set should not be connected to any other power sources such as the public distribution network In specific cases where there is a reserve connection to existing electrical ne
24. circuit known as raw water is connected between the building s water supply and the drain A valve fitted upstream of the exchanger can enable and cut off circulation With automatic sets this valve should also come with an electric control solenoid valve This system s heat exchange ensures engine cooling The room needs a ventilations system and this type of installation requires a detailed study d Ventilation of the room Extractor fans and or air blowers can evacuate heat radiation from the engine and supply fresh air to the room and equipment in the case of external air coolers or lost water exchangers If fans are being used more fans rather than one large one can regulate the temperature Ventilation of the premises requires a detailed study and should take into account the atmospheric air temperature and loss of pressure of components located in the air inlet and outlet grilles sound traps etc in particular 2 3 2 13 Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring The company does not accept any responsibility regarding damage caused by these occurrences However lightning conductors can be installed on the understanding that this does not give total protection 33522903401 ind3 31 52 YSDMO 3 INSTALLATION OF MOBILE SITE SETS 3 1 General information Besides the advice and rules given for fixed sets certain arrange
25. dures must be carried out in fresh air outside in accordance with local regulations in an area well away from fire people or animals 1 3 3 Risks related to exhaust gases and fuels Generating sets should not be operated in unventilated Always follow the local regulations in force regarding generating sets and use of fuel petrol diesel and gas before using your generating set Fuel filling should be carried out when the engine is stopped except for sets with an automatic filling system Engine exhaust gases are toxic Do not operate the generating set in non ventilated areas When installed in a ventilated area the additional requirements for protection against fire and explosions must be observed Ifa burnt gas exhaust leaks the generating set may become more noisy In order to be sure of its efficiency you should periodically examine the burnt gas exhaust Pipes must be replaced as soon as their condition requires it 33522903401 ind3 9 52 YSDMO 1 3 4 Risks related to toxic products with the eyes Avoid any prolonged or repeated contact with skin It should not be swallowed In the event of skin contact wash thoroughly with water and soap In the event of contact with eyes rinse immediately with plenty of water for at least 15 minutes CALL A DOCTOR IMMEDIATELY KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN The corrosion inhibitor contains alkali This substance should not come into contact Warni
26. e breakdown of the fan Always use tools in good condition Check that you have understood how to use them before starting a procedure 33522903401 ind3 8 52 YSDMO Only fit original spare parts Use tools that correspond to the work being carried out Clean all traces of oil or coolant with a clean cloth Never use petrol or other flammable substances to clean parts Use only approved cleaning solvents Do not use a high pressure cleaner for cleaning the engine and fittings The radiator hoses electrical components etc could be damaged Avoid accidental contact with parts that reach high temperatures exhaust manifold exhaust Engage the parking brake when the generating set on its trailer is installed on the operating site When setting on a slope check that no one is behind the trailer Goggles should be worn when carrying out maintenance operations and watches bracelets etc should be removed 1 3 2 Risks related to feed gas concerns gas sets The gas is explosive It is forbidden to smoke go near or create sparks when the tank is being filled and near to the generating set Request the user technical notes and LPG or NG safety data sheets from your gas supplier BE Gas installations must be installed maintained and repaired by recognised specialists Do not attempt to open unseal or intervene in gas supply pressure relief valves and on the gas line in general Gas supply proce
27. emission will be as direct as possible The cooling system will be connected to a sealed emission sleeve or cover to prevent hot air from being recycled The air inlet and emission openings should not be located close to one another Crankcase ventilation A The vapours from the crankcase should preferably be removed outside the room in which the generating set is located to prevent these vapours from being deposited on the radiator causing it become dirty and thereby reducing its cooling capability 33522903401 ind3 23 52 YSDMO 2 3 2 9 Fuel Since the fuel is classed as a dangerous product certain regulations for storage and distribution must be followed It is also necessary to consult current laws when carrying out the installation It is usual to fit fixed installations with a daily service tank and storage tank These two tanks can be joined into one if the generating set consumption 1s low Do not used galvanised receptacles or brass coated receptacles for storing fuel Manual filling tank Solution for a manual starting generating set that is visually monitored This tank is often part of the frame and has a mechanical gauge filler neck and drain port Automatic filling tank located in the room Solution for automatic starting generating sets The tank is automatically filled by an electric drawing pump in a main storage tank This type of installation is subject to regulations Moreover it should be fitted wit
28. gines of the 4000 series it is essential to dismount the flywheel blocking device for protection of the crankshaft during transport at set commissioning before first start up 6 1 Installation checks e check that the general recommendations from the installation section ventilation exhaust fluids etc are followed e check the levels oil water diesel battery e ensure the generating set earth socket is earthed 6 2 Connection checks e check the remote controls by section and number sector accessories low voltage central control panels etc e apply voltage to the accessories to check the following components non comprehensive list gt fuel pump consumption and direction of rotation gt water preheating intensity and voltage gt battery charger etc 6 3 Starting the generating set e carry out the mechanical checks oil pressure water temperature absence of noise etc e carry out the electrical checks voltage and frequency carry out the safety checks emergency stop oil pressure water temperature etc 6 4 Load test on installation e check the rotary field e check the voltage frequency and intensity e check normal emergency switching or coupling 33522903401 ind3 40 52 YSDMO 7 BATTERY MAINTENANCE Fit the battery so that it is properly ventilated Maintenance should only be carried out by a qualified person If replacing the batteries use the same type of batteries Only
29. h a retention container capable of collecting leaks with a capacity at least equal to that of the tank There must be an overflow pipe going back to the main tank Its section should be at least twice that of the supply pipes To prevent unpriming the tank is fitted slightly filled in relation to the diesel engine except in covered parking areas This tank must also be fitted with a shut off valve for which the control must be located outside the room 1 Double lined storage tank 2 Leak testing cell ca 3 Filling port w d 4 Shut off valve control unit GL K 5 Safety valve control unit zm M 6 600 L retention container di 7 500 L daily service tank i 8 Gauge with level switch 9 Manual pump Si 10 Electric pum ectric pump cr 11 generating set p 12 Vent Si 13 Safety valve 14 Shut off valve 15 Earthing eL 16 Electric fuel level gauge 17 Anti return valve with strainer 18 Concrete floor plate 19 Anchoring belt 1 m Fuel supply 20 Pits Fuel return F Pipe passage Electrical wiring 23 UE Mechanical cable Drains 24 Min hole 0 70 x 0 70 25 Type and capacity label Diagram 2 11 Example of an installation 33522903401 ind3 24 52 JfSDM0 2 3 2 10 Burnt gas exhaust Studying the evacuation of burnt gases by a generating set should not be seen as a minor detail due to the fact that a pipe can always be instal
30. hould make the necessary arrangements to satisfy site aesthetic requirements The whole site must be kept clean and in good condition The premises must be kept clean and cleaned regularly with in order to avoid piles of dangerous or pollutant material or dust that could be susceptible to catching fire or causing an explosion The cleaning equipment must be adapted to accommodate the risks presented by such products and dust The presence of dangerous or combustible materials on premises where combustion apparatus is sheltered 15 limited to what is required for the operation The installations must be operated under the constant supervision of a qualified person This person should periodically check that the safety devices are working properly and ensure the correct fuel supply to the combustion apparatus Apart from combustion apparatus flames in any form are prohibited This should be displayed in bold on a sign Residual water mud and waste spray 15 prohibited The fuels to be used should correspond to the ones in the declaration file and the specifications prescribed by the combustion apparatus manufacturer The fuel is considered as being in the physical state that is introduced into the combustion chamber Burning waste in the open air 1s prohibited Except for where a specific agreement has been made once the gas supply main unit has been closed it can only be reopened by the gas distributor However the user may cond
31. ights prohibited No smoking 7 prohibited 0 774 Diagram 1 1 Pictograms and their meanings trailer earth the set before starting it Emergency cut out YSDMO 1 3 Safety instructions and regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual contact your dealer who will explain it to you or give you a demonstration A list of risks and precautionary measures to take follows You should also refer to any local and national regulations that apply in accordance with your own jurisdiction KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries 2 3 1 General advice Read and understand the manuals provided with the generating set in full Do not wear loose clothing and do not go near the machines when operating Note that the fans are not clearly visible when the engine 15 running Warn all people present to keep well back during operation The generating set should always be controlled by an experienced person Always test the generating set from the control panel Follow the maintenance table and its directions Never let anyone else use the generating set without having first given them the necessary instructions Do not start the generating set without first removing the protection cover and closing all of
32. in accordance with its final position carefully set down the container without jerking while continuing to position it once the container is on the ground and in the correct position release the slings check that the container is stable and correct it if not detach the slings and remove them from the lifting rings earth the generating set To do this use a minimum 25 mm stripped copper wire and 16 mm insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground the procedure has been completed when the container 15 in position 33522903401 ind3 35 52 Bsp Examples of equipment and handling LA Example of container lifting using a lifting beam Example of grip by an Example of grip by a fitted with hooks shackles or manually coupled ordinary hook safety hook locks Example of grip by a Example of shackle manually coupled lock grip Attachment of lifting device Checking the attachment when lifting the container is still on the ground Example of lifting Example of a container lifted by four parts in the bottom corners Diagram 5 1 Examples of handling equipment 33522903401 ind3 36 52 Diagram 5 3 Examples of handling methods which should not be used 5 1 2 Transport The transport of containers should be in accordance with the highway code for the relevant countries The transport equipment trailer semi
33. ing Suction or discharge clamp 9 joint 10 Screw with nut for cover or bracket to be specified 11 Piston valve 12 Seat valve 13 Valve split pin CON B WN Diagram 9 1 Pump components 33522903401 ind3 48 52 EYSDMO Suction Suction capacity is completely independent of the size of the pump These pumps can attain 7m to 7 50m of pressure suction with cold water at sea level The suction pipes should always face on an upwards slope from the fluid suction pump to the pump installation point with no top section and with as few bends as possible with a large radius For any suction over 2 metres a foot valve must be installed suction valve to hold the fluid in the pipes which should have no cracks or leaks The suction manometric height should not be confused with the vertical distance of the expanse of water to the pump Losses of pressure are inevitable and are related to the length and diameter of the pipes used according to the flow the presence of a non return valve or elbows in the pipes A non return valve or elbow causes a loss of pressure equivalent to what 5 metres of straight pipes would give When there is a certain length of pipework or high suction or discharge a larger diameter pipe than usual should be used Discharge The pumps have been tested at a pressure of 1 500 kg to 2 kg and can therefore handle a 15m discharge However the force developed by
34. ing sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to minimum For all parts replacement contact your nearest dealer representing our company who will have the necessary equipment and properly trained and informed staff to carry out maintenance parts replacement and even total reconditioning of generating sets Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance Some user manuals and maintenance manuals that come with the generating sets have instrument units and show the starting and stopping procedures for the engines For the generating sets fitted with command and control boxes that are specific to the sets only the information that appears in the documentation for the sets boxes should be taken into consideration Based on this and depending on the manufacture criteria for the generating sets some engines may be fitted with specific electric cables different from those described in the engine s documentation 1 1 2 Structure of the reference material The reference material delivered with the generating sets is divided into 3 levels 1 1 2 1 Level A This basic level gives all the user and maintenance procedures for the generating set or power station This reference material enables you to get to know the equipment operate it and
35. itionally have access to it Check for each site Always protect your hands when detecting leaks Pressurised fluids can enter body tissues and cause severe harm Risk of blood poisoning Drain and discard engine oil in a designated container the fuel distributors can collect your used oil 33522903401 ind3 13 52 YSDMO 1 4 Identifying sets Generating sets and their components are identified by means of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual Examples of identification plates PLAGUE CONSTRUCTEUR MANUFACTURER PLATE 64 530 PUISSANCE ACOUSTIQUE SOUND POWER GROUPE ELECTROGENE GENERATING SET Typo L WA 96 5 Execution bre Hamoalhogation G Version TND GO 00 Manna Ka ZI PRESSION ACOUSTIQUE SOUND PRESSURE Com Fh 7 m T mi 15 rn dB A gt _ ___ AVP 31650 0114 40 CVA2889221 001 SOM bidustthos bem roo ce ores 243 Deenp hat Dh Tai 33 A1 A1 ti e DI A8 eee ede Kg GS40002004277 AVP31650 01G Q CI 32889221 0 SDMO INDUSTRIES GS40002004277 AVP31650 01G Q CI 32889221 0 SDMO INDUSTRIES Generating set Dieselmotor JOH N 12V 4000 G60 Engine Serial Number CD4045T
36. led even in the most inaccessible areas In fact there a certain number of constraints to be considered such as drops in pressure caused by the exhaust insulation suspension noise level and air pollution It should be noted that the more complicated a circuit the more it causes drops in pressure and consequently its diameter will be large and heavy and its supports and silencers expensive NOTE Generating sets with a silencer fitted in the enclosure must be fitted with an exhaust compensator This compensator or hose will be fitted to the exhaust outlet in the cover exhaust pipes 2 elbows 3 expansion bellow 4 condensation bleed 5 bulkhead crossing roof outlet 6 exhaust outlet 7 suspension line 8 needle frame 9 base of column 10 silencer suspension 4 11 heat insulation 12 silencers Diagram 2 12 Example of an installation The installer must check that all the components installed on the exhaust pipe do not cause pressure drops greater than the engine s admissible pressure 33522903401 ind3 25 52 YSDMO Figure Pipes It is recommended that you use seamless pipes However for weight reasons rolled steel pipes can be used In any event welded bars inside the duct are to be avoided Figure 2 elbows The elbow should have a minimum curve radius of 2D 1f possible in a single component If the elbow 1s made of welded steel check that it includes at least 3 sectors fo
37. lencers they can be vertical or horizontal Diagram 2 21 Brackets Figure 11 heat insulation Depending on the type of installation you may have to insulate the heat released in the room Once it has been insulated the surface temperature should not exceed 70 C The recommended material is rock wool excluding asbestos and eventually it can be recovered with aluminium sheets to improve the look of the installation and the thermal insulation 50 mm thick glass wool should be considered a minimum requirement Figure 12 silencers These reduce noise by absorbing or causing phase differences in the sound wave An exhaust should be effectively suspended the supports should never rest on the set except for original fittings An exhaust compensator will be fitted to the engine outlet The pipes will never have a diameter less than the set refer to us about vermin and be directed so that gas cannot return to the room The pipes should be fixed so that their weight is not supported by the compensator It should be perfectly straight any misalignment could lead to a rupture Adapted silencer The adapted silencer is fitted directly to the set or cover It is an absorption type silencer A compensator is fitted between the engine and exhaust in the covered version Diagram 2 22 Adapted silencer 33522903401 ind3 28 52 SDMO Absorption silencer The gas passes through a sound proof duct made of acoustic high
38. maintain it both on a daily basis and periodically The reference material for the engines and alternators fitted to the sets consists of engine user and maintenance manuals from the manufacturer and alternator user and maintenance manuals from the manufacturer Level A reference material contains the user and maintenance manual containing among other things o general recommendations and safety regulations to be adhered to general recommendations for installing generating sets o general instructions for preparing generating sets before putting them into operation o Tables of capacities lubricants and coolants and fuel tanks of different engines that may be fitted to the sets according to their configurations covered or not o general reference material for maintaining starter batteries user manual for the control panel if fitted wiring diagrams these diagrams are supplied with reference material or delivered with the generating set user and maintenance manual for the engine fitted to the set maintenance manual for the alternator fitted to the set 33522903401 ind3 5 52 YSDMO 1 1 2 2 Level B This reference material 15 additional to the level A reference material In addition it contains the spare parts catalogue for the engine fitted to the set and enables qualified user to identify a part and order it Composition List index mark description part number etc Illustrations index mark The
39. ments must be made for site sets 3 2 Specific arrangements An area will be reserved to install the generating set Its should be flat and strong enough so that the generator does not sink into it It could be made of concrete or even large planks fitted together It should be noted that a generating set that does not rest correctly on its base frame or trailer will be subject to vibrations that could cause damage to all the equipment The location of the set on site should be chosen for ease of fuel supply and distribution of current to the users Access to the set s doors should be available at all times for safety and maintenance reasons Ventilation of the generating set should not be affected if there are different objects close by It will cause abnormal heating and reduced power Burnt gas evacuation will take place in such a way that there is no reaspiration into the air filter or cooling system The generating set s neutral speed must be used to protect people The generating set will need to be earthed To do this use a minimum 25 mm stripped copper wire and 16 mm insulated cable connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground These sets are to be covered or protected from bad weather by a suitable construction see previous sections 33522903401 ind3 32 52 YSDMO 4 ROAD TRAILER 4 1 Trailer linkage Before attaching the trailer check the
40. ng The anti rust product is toxic and dangerous 1f absorbed Avoid any contact with skin or eyes Read the instructions on the packaging Glycol is a toxic product and dangerous if absorbed Avoid any contact with skin or eyes Read the instructions on the packaging Never expose the equipment to liquid splashes or rainfall and do not place it on wet ground Always use the recommended fuels Using low quality fuels risks damaging the engine and altering performance The battery electrolyte is harmful to skin and especially eyes If splashes get into eyes rinse immediately with running water and or a 10 diluted boric acid solution Wear protective eyewear and strong base resistant gloves for handling the electrolyte 1 3 5 Risk of fire burns and explosion The engine should not be operated in areas containing explosive products There is a risk of sparks forming where all electrical and mechanical components are not shielded Beware of creating sparks or flames and do not smoke near batteries as the electrolyte gases are highly flammable especially when the battery 1s being filled Their acid is also harmful to the skin and particularly the eyes Never clean lubricate or adjust an engine when it is in operation unless you are qualified to do so in which case extreme care must be taken to avoid accidents Never make adjustments that you are not familiar with Never cover the generating set with any material
41. ng to the manufacturer s instructions and should check that the apparatus is operating correctly The user should create or obtain a document describing modifications and showing alterations made to the installations in relation to the original document 33522903401 ind3 12 52 YSDMO Manufacturers notes should be available to technical staff on site 1f possible The internal network diagram should be displayed as close as possible to the access points showing all the individual points Internal and external network information can be contained in a single distribution diagram sign on the door identifies and gives details of the operating company and includes the telephone number for the gas supplier emergency department Personnel should be aware of the layout of the premises and they should be identified on site to simplify procedures In the event of a problem this type of knowledge about installations 15 crucial when poor identification of the premises might make a situation worse Written operating instructions must be available for operations that involve dangerous handling procedures and driving installations In particular these instructions prescribe o Operating modes o Frequency of testing for safety devices and devices for handling pollution and other harmful substances generated by the installation o Methods for maintenance checking and use of adjustment equipment and safety devices Hi The operator s
42. ns 3 4 and 5 contain only general recommendations 2 1 Unloading 2 1 1 Safety during unloading In order to unload generating sets from their transport mountings under optimum conditions of safety and efficiency you should check that the following points are being followed correctly Suitable lifting vehicles or equipment for the work Slings positioned in the rings provided for this procedure or lifting arms resting fully underneath the frame cross beams Suitable ground to accommodate the load of the set and lifting vehicle without strain if not put down sufficiently strong and stable boards Remove the set as close as possible to its place of use or transport 1 a clear space with free access 2 1 2 Example of equipment used crane slings lifting beam safety hook shackles fork lift truck 2 1 3 Instructions for unloading 2 1 3 1 Slings attach the lifting vehicle slings to the rings on the generating set designed for this procedure hang the slings carefully check that slings are correctly attached and the equipment 15 solid lift the generating set carefully direct and stabilise the set towards the chosen position carefully set down the equipment while continuing to position it release the slings then detach and remove the lifting rings The slings must be perpendicular to the frame in order not to interfere with the set no rubbing Diagram 2 1 Hoisting a genera
43. opping up fluid charging etc If electrolyte comes into contact with your skin or clothes wash it off immediately with plenty of water Then wash thoroughly with soap If electrolyte comes into contact with your eyes rinse immediately with plenty of water and see a doctor as soon as possible Should you accidentally swallow electrolyte gargle with plenty of water then drink lots of water Consult a doctor immediately Large quantities of electrolyte should be rinsed off using a neutralising agent A common method is to use a solution of 500g of bicarbonate of soda diluted in 4 litres of water The bicarbonate of soda solution should be added until the reaction has finished lather The remaining liquid should be rinsed off with water and left to dry 33522903401 ind3 41 52 YSDMO PROCEDURE FOR TESTING STARTER BATTERIES TEST TYPE PROCEDURE RESULT ACTION THE TERMINALS DAMAGED BLACK ADD WATER UP TO THE PRESCRIBED LEVEL CHECK THAT THE REPLACE THE BROKEN THAT THERE IS NO ELECTROLYTE CHECK THE TRAY AND LEAK AND CHECK NO DAMAGE ELECTROLYTE TERMINALS THE CONDITION OF LEVEL CHARGE FOR 4 5 HOURS VISUAL 1 10 OF THE INSPECTION NOMINAL CAPACITY THEN CHECK THE ELECTROLYTE DENSITY BELOW THE step 2 PRESCRIBED LEVEL CHECK THE PRESCRIBED LEVEL ELECTROLYTE DENSITY sten 2 ELECTROLYTE LEVEL lt 1 22 OR VARIATION ABOVE 50 21 BETWEEN CELLS lt 122 kg l OR VA
44. or the variations in the volume of coolant fluid according to the temperature 33522903401 ind3 30 52 YSDMO b Air recooler The engine cooling circuit is connected to an air recooler located inside or outside the room in order to implement this procedure When located in the room it operates in the same way as a ventilated radiator The fan is either attached to the diesel engine or run by an electric motor If the air recooler is moved outside on the roof or in another room the coolant pipes are extended and cooling ventilation is supplied from another room In these installations the degassing conditions should be considered even more carefully than for a radiator In all cases the air cooler is cooled by the fan For cooling by radiator or air cooler in the room the increase in temperature due to heat radiation for the sizing of the installation should be taken into account c Lost water exchanger This type of cooling consumes a non negligible degree of water and hence there 15 an operating cost to be taken into account This the solution when local provisions ensure the flow of water and do not allow the ventilation provisions to be made for cooling by a ventilated radiator or air recooler These lost water installations consist essentially of an exchanger with one of its circuits fitted with an expansion receptacle connected to the engine cooling circuit The latter s water pump ensures circulation The second exchanger
45. order not to be vulnerable to future legal action On this subject the sound level of the set and reverberation effects on buildings must be taken into account Diagram 5 5 Examples of increase in sound level caused by reverberations and the sound directivity The equipment should also be installed so that the vents controlling the air intake should be opposite so that there are no difficulties in difficult weather conditions intake of air snow sand etc Remove the blanking piece s from the exhaust outlet s used for transporting it and replace them with the extension cable s supplied with the generating set Diagram 5 6 Removing the blanking piece 33522903401 ind3 39 52 YSDMO 5 2 Maintenance lubricate the hinges and locks regularly lubricate the joints with silicone grease wash and clean the bodywork using products designed for car bodywork check the condition of the bodywork and retouch any scratches straight away to prevent the start of corrosion 6 PREPARATION BEFORE OPERATING THE SET The inspections referred to in this section enable the electrical generating set to A operate Specific skills are required to carry out these operations Warning They must only be entrusted to personnel with the necessary skills Failure to follow these instructions in any way could lead to incidents or very serious accidents Generating sets fitted with MTU en
46. r 90 elbows Diagram 2 13 Pipes and unions Figure 3 expansion bellows and hoses expansion bellow absorbs sideways movements due to expansion approx Imm metre 100 C hose allows for considerable sideways travel but low longitudinal amplitude Figure 4 condensation and rainwater bleed Allowed for in the lower section of the installation to protect the silencer and engine or for any changes in horizontal vertical travel C Diagram 2 15 Bleed valves ES Ze r Figure 5 bulkhead crossing roof outlet For each bulkhead passage and roof outlet Diaeram 2 16 Bulkhead connectors 33522903401 ind3 26 52 SDMO Figure 6 exhaust outlet The exhaust outlets disperse the gases in the atmosphere and protect the inner section of the pipes from bad weather Figure 7 suspension line Generally made up of a flat iron ring attached to the ceiling The suspension line enables the pipes to expand freely Diagram 2 18 Pipe suspensions Figure 8 needle frame Used for vertical sections the needle frame allows the pipes to expand while holding them laterally Diagram 2 19 Needle frame Figure 9 column base The column base is designed to hold the weight of the vertical pipes Diagram 2 20 Column feet 33522903401 ind3 27 52 SDMO Figure 10 silencer suspension line The silencer suspension lines are designed to hold the weight of the si
47. ral removal of the set can be carried out Diagram 2 8 Example of the size of a covered generating set site 2 3 2 3 Construction All sorts of shelters can be designed to house a generating set If noise level and speed of starting are not the main considerations in your choice it can be installed under a basic shelter to protect it from bad weather rain snow storms If a low noise level and fast start are important criteria e g emergency set or noise sensitive area particular attention will be given and the room will be built of framing concrete or solid concrete blocks 20 cm minimum covered in absorbent fireproof and insulating material The fire test should comply with current legislation according to the type of building 2 3 2 4 Base of the set An operating generating set generates a certain amount of vibratory energy This vibratory energy makes its way to the floor plate via the frame As a rule our generating sets do not require a specific floor plate as they are fitted to elastic mountings However the floor plate will be sufficiently strong and detached from the rest of the construction It will also be level smoothed by the flow and unshackled If there is a risk of vibrations being transmitted the set can be mounted on a vibration mounted floor plate insulated if necessary by a resilient material This solution is mainly used with very powerful generating sets 33522903401 ind3 21 52 Y
48. se parts catalogues are only available in English regardless of the engine manufacturer 1 1 2 3 Level C This reference material 1s additional to the level B reference material It contains the information required for major maintenance of the generating set or power station workshop repair manual This document enables an experienced user to carry out repairs to equipment following deterioration or damage Composition Illustrated text index mark commentary procedure intervention period required level etc Tools list This reference material exists mainly in English regardless of the engine manufacturer 33522903401 ind3 6 52 SDMO 1 2 Pictograms and their meanings Warning Warning risk of electric shock Warning toxic materials Warning pressurised liquids Warning high temperature risk of burns Warning rotating or moving parts risk of getting caught in the machinery Warning corrosive product Earth 33522903401 ind3 Publications delivered with the generating set must be referred to Protective clothing must be worn Your eyes and ears must be protected Periodic maintenance must be carried out Battery level must be checked Lifting point required Stacking point required 7 52 Warning risk Z of explosion b Entry prohibited to non authorised 7 persons Naked flames 3 unprotected l
49. ted to moving the set Use lifting units to lift the generating set Always make sure that the lifting equipment is in good condition and has a sufficient lifting capacity n order to work in complete safety and prevent the components fitted to top of the engine from being damaged the engine should be lifted with an adjustable boom All chains and cables should be parallel to one another and as perpendicular as possible to the top of the set If other equipment fitted to the generating set alters its centre of gravity special lifting devices may be required to maintain the correct balance for working in total safety Never carry out work on a generating set that is suspended on a lifting device only 1 3 9 Recommendation for the operator and environment Operating personnel should be aware of the safety and operating instructions These will be regularly updated Operating should be monitored directly or indirectly by someone designated by the operator who is familiar with the installation and dangers and problems regarding products stored and used in the installation No one from outside the establishment should be able to access the installations freely unless designated by the operator The user should check the service pressures of the different pressure stages making sure that they are in accordance with the prescribed operating requirements The user is also responsible for making the apparatus adjustments accordi
50. tery mantenan OPEC OT 41 8 Fuel and Consumibles uiii du do ide 43 QUII iii PAPE A uu OO 43 5 2 Circuit Capacities Rees 44 8 5 Circuit Capacities Mitsubishi engines 44 8 4 Circuit capacities John Deere engines 45 5 5 Circuit Capacities MTU EEN 46 8 6 Circuit capacities GMC engines Nevada 47 8 6 Circuit Capacities Perkins TE 47 9 Maintenance of optional equipment 46 91 pumps tor clcar IT E 48 9 1 1 Technical specifications 48 9 1 2 Maintenance and repalr 49 OZ FAT OA pi yku uuu TI UU 50 LIN RENE E Um 50 9 2 2 __________________ 51 2 E Rd __ ______ 51 D POP IDC u uuu ___ _ 51 iu Ee 51 Ol ill A D ee E
51. the openings Engine with turbocharger never start the engine without fitting the air filter The rotating compressor wheel in the turbocharger can cause severe physical injury Foreign objects in the intake duct can cause mechanical damage Engine with air preheating starter components never use starter aerosol or similar product as starter assistance When it comes into contact with the starter component an explosion may occur in the inlet manifold and lead to physical injury Never let a child touch the generating set even when not in use Avoid using the generating set in the presence of animals can distress the animal Never start the engine without an air filter or exhaust Always follow current local regulations regarding generating sets and use of fuel petrol and gas before using your generating set Never use sea water or any other electrolitic or corrosive product in the coolant circuit B Disconnect the battery and pneumatic starter if there is one before carrying out any repair to prevent the engine from starting accidentally Fit a panel over the controls to prevent any attempt at starting Do not modify the engine Only use the correct techniques for turning the crankshaft to rotate the crankshaft manually Do not try to rotate the crankshaft by pulling or exerting force on the lever on the fan This method can cause serious physical or material harm or damage the fan blade s leading to prematur
52. the person handling the pump will increase according to the flow and elevation height suction discharge Therefore with a low flow the fluid can be raised higher than with a large flow pump Draining A small tap or bolt about 0 70m above the pump is indispensable Fitting The pump should be installed on a strictly vertical plane with Japy marque on the discharge side Check that the mounting has a flat surface and that the nuts are tightened moderately and alternately to prevent distortion of the body 9 1 2 Maintenance and repair Faults The pump no longer sucks or discharges there is air intake check all the seals and the suction pipes the foot valve suction valve no longer works there is probably dirt or some waste under the valve that 1 stopping it from resting on its seat check it there is dirt inside the pump blocking the valves remove the cover clean inside and check that the valves move freely Cable gland leak tighten the two cable gland bracket nuts alternately by one or two turns Otherwise remove this bracket take out the cable gland which 15 located in its housing Clean this housing and remove the residual lining Replace it with graphite braiding if it is a pump without cable gland model 254 remove the cover replace the O ring checking that the piston axis is not oxidised If it is clean it carefully Also reline the groove with graphite braiding 33522903401 ind3 49 52
53. ting set 33522903401 ind3 16 52 YSDMO 2 1 3 2 Fork lift truck position the arms of the fork lift under the frame making sure that only the cross beams are resting on the arms lift and handle the equipment carefully set down the generating set in its unloading position Diagram 2 2 Transporting a generating set on a fork lift truck 2 2 Handling instructions carefully lift the edge on the engine side with 2 jacks then slide 3 pipes under the frame leave the frame under the pipes then move the set by pushing manually while the set is being moved use the freed pipes by sliding them one after another under the frame when it has reached the desired location position the set then lift it up using jacks to support it remove the pipes and put down the set checking that it is in the correct position then remove the jacks Diagram 2 3 Handling a generating set using rollers 33522903401 ind3 17 52 SDMO It is recommended to use a fork lift truck with arms that are longer than the width of the frame Diagram 2 4 Handling a generating set with a pallet truck If you are using a rail or crab once it is in position continue in the same way as described in the slings paragraph Diagram 2 5 Handling a generating set using a mobile winch 33522903401 ind3 18 52 SDMO 2 3 Installation of fixed sets NOTE If you do not follow the basic principles the installation assembl
54. trailer hook on the tow vehicle it should fit the trailer ring perfectly to serious accidents Also check Warning no incipient fractures or excessive wear on the hitching system Waming locking system is operating properly Trying to tow a trailer with non matching device bar wires cords etc could lead To hitch the trailer proceed as follows lock the wheels to stop the trailer from moving lift up the rear trailer supports and lock them release the parking brake release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook hitch the trailer remove the locks on each side of the wheels then lift up the front wheel fully using its handle connect the electrical circuit of the trailer to that of the tow vehicle hook the handbrake safety wire onto the hook on the tow vehicle CORRECT CORRECT INCORRECT Diagram 4 1 Coupling a trailer Tow vehicle Tow vehicle INCORRECT Tow vehicle Tow vehicle Trailer 33522903401 ind3 33 52 EYSDMO 4 2 Check before towing Before towing carry out the following checks wheel torquing lock trailer hook tyre pressure light signals working cover doors closed parking brake off front wheels and rear supports lifted tightening and fixing the draw bar arms locking levers brake test for road type trailers fitting brake safety cable 4 3 Driving
55. tworks it must only be carried out by a qualified electrician who should take the operating differences of the equipment into account according to whether the public distribution network or generating set is being used Protection against electric shocks is ensured by an assembly of specific equipment If this needs to be replaced it should be by components with identical nominal values and specifications Due to strict mechanical specifications you should only use flexible resistant rubber sleeved wires in compliance with CEI 245 4 or equivalent wires 33522903401 ind3 11 52 YSDMO 1 3 7 Dangers presented by electric currents first aid First aid In the event of an electric shock cut off the voltage immediately and activate the set s emergency stop If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe Take extreme care to avoid the electric arc that results from this Begin emergency procedures Resuscitation If breathing has stopped begin artificial respiration at once in the same place the accident took place unless the victim or operator s life could be endangered by this In the event of cardiac arrest carry out cardiac massage 1 3 8 Risks rela
56. use insulated tools the operator should not be wearing a watch bracelet or any metal object Never use sulphuric acid or acid water to top up the electrolyte level Batteries release oxygen and hydrogen gas which are flammable Never use flames or generate sparks near the battery since flames or sparks can cause an explosion Discharge any static electricity before handling the batteries by first touching an earthed metal surface Do not use the battery when the fluid is below the minimum required level Using a battery with a low electrolyte level could result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables remove the cable from the negative terminal first When reconnecting the battery connect the positive lead first Charge the battery in a well ventilated area with all filling hole plugs removed Make sure the cable clamps are correctly secured to the battery terminals A loose cable clamp can cause sparks that could result in an explosion Before servicing electrical components or performing electric welding set the battery switch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery t
57. y will suffer damage and abnormal wear The procedure described gives the main requirements for installing a conventional generating set made up of a heat engine a generator and electric panel These requirements are general principles to be observed For any specific applications or if you have any doubts our technical departments will advise you and look at your specific conditions of installation The current regulations provisions and laws in installation locations must be adhered to AIR EMISSIONS Air is evacuated by the radiator through the wall The opening in the wall should correspond to the size of the radiator and should be fitted with a rain grille FUEL STORAGE Storage should comply with current regulations The retention container can be made of steel or masonry FUEL PIPES Fuel supply and return in a duct EVACUATION OF EXHAUST GASES OUTSIDE THE ROOM If the original pipework needs to be extended it must be suspended and fitted with an expansion joint inserted between the pipes and the silencer or engine In any case it must not rest on the wall or silencer The exhaust pipework must be FIREPROOF DOOR free of any movement through the walls or partition the masonry ELECTRIC WIRES The path of wires may be Installed in ducts or In this case the wires must be installed in a cable tray AIR INLET Air inlet grille on the door or on SECURING EARTH THE UNIT TO THE F
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