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Operation & Maintains Manual of Weichai Group Diesel Gen-set

1. Figure 3 7 AS480 structure and wiring diagram 1 Terminal 7 and 8 are connected to main stator armature of alternator and terminal Fl and F2 are connected to stator magnetic field of exciter 2 Terminal and 2 are used for external connection of voltage regulator thus they must be short connected if external voltage regulator is not installed 3 When this Gen set 1s connected in parallel SI and S2 are used for connection of regulating current transformer 4 Stability adjustment shall be selected as per Table 3 3 Table 3 3 Stability selection list Response speed BD Gow No connection 100kW BC 100kW 5 See Table 3 4 for roles and adjustment methods of AVR adjustment potentiometer Table 3 4 Function list of AS480 adjustment potentiometer Control button Direction of adjustment 15 Voltage Droop applicable for parallel connection Stability UFRO Under Frequency Roll Off 3 4 KRS440 Connect external voltage regulating potentiometer Remove short connected jumper during installation Detection input voltage selection input Connection droop CT pe Connect PF controller Over excitation protection K Connect La Lb under 110 120V E Diesel Gen set Operation Instructions Turn clockwise to Adjust output voltage of alternator increase output voltage Droop is 5 when power Turn clockwise to factor of Gen set 1s Gen set increase droop as l Tu
2. sd oil Viscosity of machine oil decreases due to Clean cooling system and oil cooler high temperature which reduces oil pressure ee Leakage of lubricating oil circuit of diesel 4 Replace the leaking part engine Clean the oil filter and replace filter Blocking of oil filter element if necessary 5 EE NE Suction filter of oil pump is blocked Clean the suction filter instructions The machine oil goes bad or is mixed with TP n Replace machine oil with method in 7 other liquids which decreases viscosity and thereby reducing oil pressure EN Oil pump capacity is insufficient Replace oil pump Fit clearance between crankshaft and Replace main bearing and connecting rod bearing is too big due to wear and tear bearing after long term use 6 High coolant temperature Serial E Cause Elimination method number Coolant is insufficient Fill coolant to 5cm below the tank cover l Contact with after sales service personnel 2 Fault of water pump to repair or replace Contact with after sales service personnel 3 Fault of thermostat to repair or replace Hose is damaged Replace the connecting hose i Clean the radiator See Chapter 9 for 5 Radiator is blocked method 7 Fuel consumption is too high Serial RE Cause Elimination method number ur Contact with after sales service personnel l Fault of fuel injector to repair or replace Poor quality of diesel Select fuel of
3. Diesel Alternator Set Operation Instructions diesel engine and detect engine oil level by the dipstick on oil pan The level shall be proper when it is higher than L lower level scale mark and lower than H higher level scale mark ALi FR Oil dipstick uh Figure 7 2 Engine oil level 3 Refueling 3 1 Fuel selection Selection of grade as per GF252 2000 is as shown below No 10 light diesel oil applicable for diesel engine with preheating equipment No 5 light diesel oil applicable for the regions where lowest air temperature 1s above 8 C No 0 light diesel oil applicable for the regions where lowest air temperature is above 4 C No 10 light diesel oil applicable for the regions where lowest air temperature is above 5 C No 20 light diesel oil applicable for the regions where lowest air temperature is above 14 C 50 Diesel Alternator Set Operation Instructions No 35 light diesel oil applicable for the regions where lowest air temperature is above 29 C No 50 light diesel oil applicable for the regions where lowest air temperature is above 44 C 3 2 Method for refueling Fill fuel to daily use fuel tank fully In the Gen set the light diesel oil of specified grade and sulfur content 1s not higher than 0 5 shall be used as the fuel Warning when filling fuel to fuel tank do not smoke or use open flame nearby because this usually would cause a risk of fire or exploration 3 3 Fue
4. mig az Figure 3 14 Electrical Schematic Diagram of DSE7320 Module s Automatic Change Over Electronic Governing Gen set 30 Diesel Alternator Set Operation Instructions Chapter 4 Main Specifications and Technical Parameters of the Gen set 400 400 400 400 400 Rated current A Rated power factor lagging Coolant volume L Lubricating oil volume L Maximum allowable exhaust back pressure kPa Rated load fuel consumption L h LI 2600 1050 1630 Battery voltage V 12 12 12 24 24 31 Diesel Alternator Set Operation Instructions Battery capacity A h Shuangdeng 40 2 40 2 0 145 0 143 0 143 0205 0205 Raten a 0 s 9 m J m Rated power factor lagging Maximum allowable exhaust back pressure kPa Alternator insulation grade 2800 X 1050 X 1630 2800X 1050X1630 32007 11007 1750 320011001750 3200X 11003 1750 32 Diesel Alternator Set Operation Instructions Battery voltage V 24 24 24 24 24 2 032 z Note 1 Above main specifications and technical parameters of the Gen set are for reference only We reserve the right to optimize and change design the Gen set and change parameters without further notice 2 The Gen set of other voltage and frequency etc can be customized according to requirements of customers 33 Diesel Alternator Set Operation Instructions Chapter 5 Transportation of the Gen set The diesel Gen set shall be provided with necessary s
5. 26 Diesel Alternator Set Operation Instructions respesp zo es estas oe oc 5 L2 32 13 Hug 3 0 mE wo Epp Te Es Te Tr e Ts popu al usb id ul el wil te alm 843 1 EAE WRIT lii m E ee TENE nn fon REE TE Mater T MEAE HERUM FREMITU SUR I NRI TAT WETCHAT POWER GENERATION CO Figure 3 11 Electrical Schematic Diagram of DSE6020 Module s Automatic Change Over Mechanical Governing Gen set 27 Diesel Alternator Set Operation Instructions i MOMS SOO MEES CHE POUSSER Att Ht Hi Re HB iat oup b ang E DE x falle slelrbalslehp aper oo a 22 za t 25 z4 co 3 32 32 33 ao Mf WM 3 33BMuNtut 8M 9 LER ich SS a a ER A Dr ces PT Figure 3 12 Electrical Schematic Diagram of DSE6020 Module s Automatic Mechanical Governing Gen set 28 Diesel Alternator Set Operation Instructions 3 400V 50Hz OUTPUT D Sgen ilio OUTPUT C GEN OF FUEL DATPUT E IDLE P25 TS EPEC AET DT papa c22 tenem mera mm mm ff Tr Ts fs Ds e Du s e e De Tv Ts nooo ooo JEJE ee Figure 3 13 Electrical Schematic Diagram of DSE7320 Module s Automatic Electronic Governing Gen set 29 Diesel Alternator Set Operation Instructions Im 400v 50Hz M2 La L2 3 1A 1HEADE JA SOLOW ga D n sen DI I r I l Kaz OUTPUT D GEN ON hee OUTPUT C MANION LL sj pa 7 eji s 2 DT
6. 3 Terminal 1 and 2 are used for external connection of voltage regulator thus they must be short connected if external voltage regulator s not installed 4 Terminal La and Lb are only applicable for some special low voltage applications 5 When this Gen set is connected in parallel SI and S2 are used for connection of regulating current transformer and Al and A2 are used for connection of VAr PF controller 6 Stability adjustment shall be selected as per Table 3 1 Table 3 1 Stability selection list Response speed BD 100kw 100kW 100 550KW 550kW 7 Frequency selection is as shown in Figure 3 4 12 Diesel Gen set Operation Instructions 8 See Table 3 2 for roles and adjustment methods of AVR adjustment potentiometer Table 3 2 Function list of AS440 adjustment potentiometer No in Control button Function Direction of adjustment figure Adjust output voltage of Turn clockwise to Voltage alternator increase output voltage l Droop applicable for Droop is 5 when power Turn clockwise to parallel connection factor of Gen set is 0 increase droop Turn clockwise to Increase analog input 3 Fine adjustment T Increase gain or sensitivity sensitivity T uu Turn clockwise to n 00 Set over excitation tripping MEN 4 Over excitation tripping increase tripping trigger trigger potential potential n l Turn clockwise to 5 Stability Prevent voltage swing i increase damping effect
7. Be sure to spray protective oil to all machined parts and parts easy to be rusted on diesel engine 8 Nozzle of intake and exhaust pipe silencer shall be closely wrapped with a 74 Diesel Alternator Set Operation Instructions piece of plastic cloth to prevent foreign objects and moisture from entering into 9 Seal up after above procedures are completed 8 3 If AC alternator is not used for a long period of time moisture may enter into the coil and cause corrosion In order to reduce condensation of moisture as much as possible place AC alternator at a dry place and keep its coil dry with a moisture remover if possible 8 4 Followings shall be paid attention to during storage of battery it shall be kept in a dry clean and well ventilated room in which temperature is 5 25 C be kept away from direct sunlight heat source any liquid and hazardous substances do not be placed upside down or on the side and prevent from being impacted or weighted After long period of service the battery itself may discharge slowly or even scrap Therefore n order to ensure that the battery is always in good operating state recharge it at regular intervals Suggested charging interval 1s as follows Recharge once every 6 months when storage temperature 1s less than or equal to 20 C Recharge once every 3 months when storage temperature is 20 30 C Chapter 10 Common Failures and Troubleshooting 1 Diesel engine does not start
8. Owing to the fact that viscosity of engine oil depends on temperature to a large extent and will reduce significantly with increasing of temperature n order to ensure that diesel engine can be operated in a safe and reliable way please select the most appropriate engine oil according to ambient temperature by referring to figure 7 1 48 Diesel Alternator Set Operation Instructions Ambient temperature Figure 7 1 Selection of lubricating oil grade In China it is recommended to select lubricating oil grade as below gt Select SAESW 30 grade lubricating oil in northern region Select SAE15W 40 grade lubricating oil in Central China Select SAE20W 50 grade lubricating oil in southern region You are recommended to use Weichai Power s dedicated 15W 40 engine oil which is mixed with imported high quality base oil and well chosen additives and sold by various service outlets at a unified price in China Note do not use CD grade or below lubricating oil on the Gen set Be sure to replace engine oil filter every time the engine oil is replaced Note using of lubricating oil which does not meet above requirements may cause operation loss and reliability performance reduction of the Gen set Warning the engine using lubricating oil of incorrect type or quality grade is beyond the scope of warranty 2 2 Method for refilling of oil Refill engine oil to lubrication system from engine oil filler at cylinder head of 49
9. UFRO Turn clockwise to Under Frequency Roll Set UFRO knee point decrease knee point Off frequency 3 2 BE350 13 Diesel Gen set Operation Instructions A B Notes For 50Hz alternator its frequency C jumper shall be moved to 50Hz terminal For remote adjustment use a 2Kohm and 0 5W potentiometer adjustment range is up to 10 Figure 3 8 BE350 wiring diagram 1 F and F terminal of the regulator shall be connected to positive and negative electrode of brushless exciter s excitation winding respectively If DC resistance of excitation winding 1s less than 21Q and exciting current under full load is not greater than maximum continuous rated current of regulator excitation winding must be connected with a enough large resistor in parallel until the resistance reaches to 219 2 Excitation winding and regulator of exciter obtain power from output end of alternator The acceptable power input range is 171 264Vac and power input is connected to terminal 3 and 4 3 3 AS480 14 Diesel Gen set Operation Instructions Connection of excitation gain starting system EBS Manual trimmer optional Ar Stability connection p Y 4 gt 100kW lt 100kW 100kW VOLTS mF Slow Slow EEE e M o om l DROOP F Connecti Connecti connectio 1 STABILITY GA EtE Droop C T optional EH Remove connection before installation LED Krim UFRO connection
10. alternator The control panel of DSE6020 module or DSE7320 module can be provided with mechanically governing or electronically governing diesel engine Structure of the control panel of DSE6020 module is as shown in Figure 3 8 18 Diesel Gen set Operation Instructions DSE6020 module Door lock Power switch Emergency stop button Figure 3 8 Control panel diagram 1 DSE6020 display module 6020 module of Deep Sea Electronics is an AMF ATS module which is able to display various parameters of engine speed oil pressure water temperature fuel level and battery voltage parameters of alternator frequency three phase voltage L L and L N and current power parameters of alternator kVA kW PF kVAR kWh kVAH and kVARH parameters of mains power frequency three phase voltage L L and L N contains 7 inputs and 6 outputs 4 outputs can be customized in MPU version and 6 outputs can be customized in CAN version and sets programs by panel or software Display content and input output port of DSE7320 display module of the Gen set with different configuration may be different slightly 19 Diesel Gen set Operation Instructions Ma BIOr state isplay Display scroll utton Alarm _ indicator light Page button information Stop mode Manual mode Test mode Auto mode Silence LED Engine starting test Figure 3 9 DSE6020 module Display various parameters of Gen set Page down Press this button to display deta
11. applicable when AMF function is used is switched on green light turns on 16 When common alarm s generated green light turns on 17 When low oil pressure alarm 1s generated green light turns on 18 When high water temperature alarm is generated green light turns on 19 When AUTO mode is enabled green light turns on Note 4 LED indicator lights are customized according to actual needs in 16 19 and these 4 LED indicator lights customized here are taken as an example only 2 Power switch Control power on off of control panel 3 Emergency stop button Press this button to stop the Gen set immediately when any emergency occurs And the Gen set s unable to be started under this state When the emergency situation is over the Gen set can be started only after emergency stop button is released 4 Air switch Except closing and opening of circuit it is still available for short circuit and serious overload protection of circuits or electrical equipment 25 Diesel Alternator Set Operation Instructions 3 Electrical schematic diagram ERR 1 BEREIT cli QF ER CDQ yk TA rg FERE KA ep Do RF Mal GF REM 2 RAHETERA a Se Name HE Drawing Now a ee P00000064001 FERRI ESO AY o asas iu ex 41 34 ma TT TI AMD WI HE TM wes ree MAS Mu RAED ll yj EE RT WEICHAT POWER GENERATION CO Figure 3 10 Electrical Schematic Diagram of DSE6020 Module s Mechanical Governing Common Functional Gen set
12. 1 1 Table 1 1 Meanings of safety symbols used on Weichai Gen set Symbols A warning meaning that there is some immediate danger that may cause serious injuries or even death if cannot be avoided A warning meaning that there is some potential danger that may cause serious injuries or even death if cannot be avoided A warning meaning that a potential risk that may cause minor or moderate injuries if cannot be avoided No lifting No smoking No switching on Beware of burns Diesel Gen set Operation Instructions Beware of hot surface Beware of electric shock Beware of rotating parts Beware of auto starting Must be grounded Lift up the Gen set from here Transport with a forklift from here Diesel Gen set Operation Instructions Chapter 2 Operating Conditions and Purposes of the Gen set Diesel Gen set is a diesel fueled small s ze electro mechanical power generation equipment in which alternator produces electric energy under driving of diesel engine prime motor It converts heat energy combustion of diesel oil into mechanical energy power inverse rotation and electric energy AC alternator cuts magnetic field finally In this process fuel is its raw material and electric energy is its product I Description on model of the Gen set Model of the Gen set consisting of four parts 1s named as per following rules Series code Structural form code Reserve capacity of the Gen set k
13. 10 Other requirements Sewage discharge during operation and maintenance of Gen set water and oil sewage needs to be discharged and sewage trench shall be designed in order to discharge sewage Fire protection equipment room shall be equipped with fire extinguishers Lighting facilities equipment room shall be equipped with necessary lighting facilities 44 Cold air III Standard equipment room arrangement of the Gen set Exhaust pipe suspension Bellow Silencer Air direction ee Inr ELE x al em n evo pe LE M s Im teal it shrine ge 45 Diesel Alternator Set Operation Instructions Fire fighting equipment Sewage trench 80mm in depth and 80mm in width me are E Cum PEDES gt IE ul E i ru LE ERIT equipment Cable trench to power distribution room Outlet of sewage trench Diesel Alternator Set Operation Instructions Chapter 7 Commissioning of the Gen set Carry out commissioning as per following methods after the Gen set is installed I Inspections before commissioning l Areas at around Gen set shall be cleaned up and unsafe objects shall be moved away in order to prevent operation from being influenced or danger from being caused and ensure that intake exhaust duct for ventilation of equipment room is not blocked 2 Before inspection check if key switch of control panel is OFF and emergency stop switch is ON 3 Check all
14. AVR by analog input accessories 3 5 Regulating method of AVR Adjustment potentiometer on AVR has been set when being delivered from factory so it 1s unnecessary to adjust other buttons at random except voltage and stability button 1 Adjustment method of voltage 17 Diesel Gen set Operation Instructions Counterclockwise turn voltage adjustment button on AVR to the end then place this regulator knob to middle position if the alternator is provided with an external voltage regulator Start Gen set and slowly turn voltage regulator on AVR clockwise under Rated speed until rated voltage is reached 2 Adjustment method of voltage stability When adjustment is necessary for the reason of unstable voltage following operation procedures shall be followed Let the Gen set to operate without load and check if its speed 1s correct or not Turn stability knob to the end clockwise and then turn it counterclockwise slowly until voltage of alternator starts to fluctuate Note correct setting will be completed just by slightly turning clockwise from this position namely at this point voltage of alternator is stable but it is also very close to unstable zone III Control panel Control panel is brain of the Gen set as it not only enables starting stopping data measurement data display and fault protection of engine but also enables electricity measurement electricity display and electricity protection etc of
15. Check and adjust uneven 4 Diesel engine cannot reach rated speed Troubleshooting Inspect and correct with hand tachometer or Speed display 1s incorrect 79 Diesel Alternator Set Operation Instructions digital tachometer Contact with after sale service personnel to 2 Speed sensor malfunctions mM maintain or replace Check if fuel supply pipe or fuel filter is 3 Fuel supply system 1s blocked blocked If necessary replace it There is water in diesel Replace fuel and add oil water separator Adjustment of throttle control 5 uu Check travel of accelerator lever 1s improper 5 Voltage of the Gen set is abnormal Troubleshooting There is no voltage during starting of the Gen set on a Rated speed until it reaches to Rated speed _ Remanence voltage is low Magnetize as shown below Check alternator and AVR as per Other reasons procedures of excitation separation as shown below Voltage is unstable in loaded or no load operation Speed is unstable Adjust speed regulator u l Adjust AVR stability potentiometer of AVR stability setting is engine as per the method introduced in Incorrect Chapter 3 3 Voltage is too high in loaded or no load operation l l Reduce speed of the Gen set to Speed is the Gen set is too high l 1500 1560r min Power factor is leading Capacitive load is too high 4 Voltage under no load is too low Adjust speed of the Gen set to Speed is too low 1530 1560r min a
16. Emergency stop In an emergency stop press emergency stop button or rapidly push fuel injection pump stop control handle to OFF position Note do not activate emergency stop at random unless a special emergency Occurs If any abnormality occurs during commissioning carry out troubleshooting with the method introduced in Chapter 10 57 Diesel Alternator Set Operation Instructions Chapter 8 Operation of the Gen set I Preparations and inspections before operation l Areas at around Gen set shall be cleaned up and unsafe objects shall be moved away in order to prevent operation from being influenced or danger from being caused and ensure that intake exhaust duct for ventilation of equipment room is not blocked 2 Before inspection check if key switch of control panel is OFF and emergency stop switch is ON 3 Check all electric circuits to see if wiring harness is damaged or leaks electricity or not If any replace the wire and check if the connection is loose or damaged or not If any tighten or replace it 4 Check reliability of fasteners and throttle control system confirm if various operating mechanisms are flexible portable and reliable and check pre tensioning of charger belt and fan belt 5 Check if there 1s large amount of dust accumulating on control panel and Gen set If any clean it in order to prevent electric shock or reduction of cooling performance of the Gen set caus
17. Terminal 1 2 of AVR or 6 7 of Connect terminal 1 2 or 6 7 of AVR in KRS440 s not shorted short 5 Voltage under load is too low uM Speed 1s too low Adjust speed of the Gen set to about 80 Diesel Alternator Set Operation Instructions I 1 8 008i mE UFRO setting Reset UFRO as shown below Check alternator and AVR as shown below Other reasons according to procedures of excitation separation test method 81 5 1 Inspection of Remanence Voltage Remove AVR cover plate and wires Fl and F2 or F and F of excitation stator magnetic field when the Gen set 1s still start the Gen set and measure voltage between AVR and terminal of main stator armature of alternator ASA40 and AS480 terminal 7 8 SE350 terminal 3 4 Stop the Gen set and connect wires F1 and F2 or F and F of excitation stator magnetic field to the AVR outlet box If the measured voltage 1s more than 5V the alternator should run normally If the measured voltage 1s less than 5V execute the following steps Use 12V DC current and connect the terminal of AVR F2 if AS440 KRS440 or A S480 is used or F 1f SE350 or BE350 is used to the negative electrode as shown in Figure 10 1 Note diode in the figure below must be used to protect AVR against damage 12V Battery Figure 10 1 Schematic diagram of magnetizing Note if the storage battery of Gen set is used for magnetizing the neutral line of main stator of alternator
18. Troubleshooting Starting system fails starter does not operate Power of control system is not Connect power of control system connected E Battery is low in level or damaged Recharge or replace the battery O Fuse in control chamber operates Replace fuse 7 Line fault Tighten loose connecting wire and 75 Diesel Alternator Set Operation Instructions replace aged cable Contact with after sale service Starting motor malfunctions personnel to maintain or replace 2 Fuel supply system fails starter operates but diesel engine does not start No fuel n fuel tank Refill diesel oil into daily use fuel tank Stop handle is in stop position and Check relay and line troubles does not operate during starting Contact with after sale service Stall controller malfunctions DM personnel to maintain or replace P Bleed air in fuel system see Chapter 7 There is air in fuel supply system z for specific method Clean air filter see Chapter 9 for Fuel filter is blocked specific method B Fuel sucking pipe joint of fuel Tighten fuel sucking pipe joint of fuel delivery pump is loose delivery pump Contact with after sale service Fuel delivery pump malfunctions mE personnel to maintain or replace ERBE Contact with after sale service Fuel injection pump malfunctions mE personnel to maintain or replace T Contact with after sale service Fuel injector malfunctions personnel to maintain or replace There is wa
19. and speed of diesel engine is governed mechanically adjust and lock throttle control handle to increase speed of diesel engine to approximately 1530 1560r min frequency 51 52Hz 2 Check voltage of three phase output line of the Gen set Voltage of each line shall be 400V 3 Check if water temperature and oil pressure of the Gen set is normal or not Water temperature shall be lower than 95 C and oil pressure shall be higher than 55 Diesel Alternator Set Operation Instructions 0 15Mpa 4 Check if lines of fuel lubrication and cooling system leak or not 5 Check if belched smoke is normal Belched smoke of the Gen set shall be colorless It is abnormal if large amount of black smoke blue smoke or white smoke is belched from this diesel engine 2 3 Operation with load If the Gen set operate normally let the Gen set operate under rated speed for 3 5min and close breaker after the Gen set warms up to let the Gen set operate under load At this time inspect operating condition of the Gen set The main inspection items are as follows 1 Check speed and frequency of the Gen set normal speed and frequency of the Gen set 1s separately 1530 1560r min and 51 52Hz If speed and frequency of diesel engine is lower than 1 530r min or 51Hz and speed of diesel engine is governed mechanically adjust and lock throttle control handle to increase speed of diesel engine to approximately 1530 1560r min frequency 51 52Hz if speed of
20. anti vibration pads would be worn and deformed after long period of service causing working plane of the Gen set to become uneven and causing operating condition of the Gen set to become worse accordingly 5 Ventilation system Ventilation of equipment room mainly aims to provide enough cooling air to 38 Diesel Alternator Set Operation Instructions bring away heat emitted by Gen set and provide enough air needed for combustion Design principles for ventilation system of equipment room are as follows 1 Effective intake ventilation area of air intake shutter shall be greater than air flow of radiator fan air quantity demanded for combustion 2 Air exhaust shutter shall be connected to radiator of the Gen set via heat resisting and grease proofing wind scooper Generally area of the wind scooper shall be 1 5 times of that of radiator core 3 If efficiency of ventilation is poor install a ventilating duct and adopt forced ventilation system when necessary Suggestion effective air intake exhaust area of 20 30kW series Gen set shall not be less than 0 7m and 800x800mm respectively effective air intake exhaust area of 40 75kW series Gen set shall not be less than 1 3m and 1170x1100mmj respectively and effective air intake exhaust area of 90 120kW series Gen set shall not be less than 1 8m and 1200x1400mm respectively 6 Smoke exhaust system Smoke exhaust system refers to the exhaust pipe connecting from smoke e
21. diode The rectifying component is installed on two plates with positive and negative electrodes The main rotor is connected to the rectifying component through the two plates Each plate is equipped with 3 diodes The negative plate 1s equipped with reverse biased diode and positive plate with forward biased diode Note that polarity of diode installed onto corresponding plate must be correct Good mechanical and electrical connection shall be guaranteed for diode installed onto plate The diode must be installed securely but not too tightly The recommended tightening torque is 4 06 4 74Nem Surge suppressor Surge suppressor is a metal oxide varistor connected to the diode with two rectifying plates to prevent instantaneous reverse voltage in winding from damaging the diode Without polarity this device shows an actual infinite reading in both forward and reverse directions when measured with an ordinary ohmmeter Its damage can be detected as signs of breakage can be found when it is damaged due to short circuit It shall be replaced if damaged Main excitation winding If output voltage in excitation separation test is still too low after adjustment and replacement of rectifying component inspect the winding of main rotor excitation stator and rotor one of which must have problems The resistance of excitation stator can be measured at terminals Fl and F2 F and F of SE350 Excitation rotor 1s connected to 6 bolt diode terminal T
22. filters with dedicated tools 3 4 Fill fuel to a new fuel filter 3 5 Apply lubricating oil to surface of filter seal ring before installation 3 6 Install filter with special tools and retighten the seal ring 3 4 1 turn s more after it contacts with base in order to seal it up 4 Cleaning air filter element The maximum intake resistance of diesel engine must be inspected when it operates at rated speed and full load When intake resistance reaches to the maximum allowable limit clean or replace filter element 67 Diesel Alternator Set Operation Instructions Note never operate the engine when no air filter is provided or dust and impurities would enter into diesel engine and cause early wear of engine Remove filter element from air filter and gently pat end face or flush reversely from inside to outside with compressed air to remove dust as shown in Figure 9 3 BETES High pressure air pipe VM b 4 V 11114 Pg Peg Figure 9 3 Cleaning of air filter Note do not damage the filter paper while flushing wash filter paper with water or oil or pat or knock element with force 5 Cleaning radiator 5 1 External cleaning of radiator In a dusty environment blades of radiator would be blocked by dust and debris etc and then performance of radiator will be influenced further The common method to remove these tiny impurities 1s to spray low pressure steam flow into it The impurities which are difficu
23. mains 53 Diesel Alternator Set Operation Instructions power to terminal block L1 and N1 of control panel if the voltage 1s lower than 9V 12V system or 19V 24V system in order to recharge the battery Finally press manual mode button on control panel to switch to the manual mode and LED indicator light turns on After the controller is in manual mode press g start button again to start the Gen set manually if you want to stop the Gen set press o stop button After safety supervision delay time 1s over Gen power on indicator light on controller turns on indicating that the engine is operating For automatic self switching Gen set the Gen set will simulate mains power failure after the Gen set 1s switched to AUTO mode and mains power test mode button is pressed After being started the Gen set will supply power to loads If you want to stop the Gen set press o stop button Note do not start the Gen set when being loaded namely air switch shall be in switching off position when the Gen set is started Note if starting is not successful try again approximately 20s later If starting does not realized continuously for 3 times top starting and try again after battery voltage or fuel pipe etc related trouble factors are eliminated 2 Operating capacity 2 1 Operation under idle speed After the Gen set is started successfully operate it under rated conditions to check operating state of the Ge
24. parts shall be inspected at a regular interval 3 2 Do not get close to rotating parts when wearing loose clothes because these would be wrapped in rotating parts and cause personal injuries or even death 3 3 Keep your hands away from rotating parts when the Gen set is operating 4 High temperature parts may cause injuries of operators 4 1 Do not open radiator cap when the Gen set 1s operating or immediately after the Gen set is stopped or splashed high temperature liquid would cause injuries of operators 4 2 Do not try to touch exhaust pipe turbocharger high temperature coolant and other high temperature parts of the Gen set with your hands when the Gen set is operating or your hands would be burnt 4 3 Owing to the temperature of exhaust pipe is high and in order to prevent burns the pipe shall be wrapped with heat resisting materials e g glass fiber or aluminum silicate etc in order to complete thermal insulation In addition exhaust terminal and exposed part of exhaust pipe shall be kept away from woods or other flammable substances especially the fuel piping II Safety symbols Diesel Gen set Operation Instructions Following safety symbols used on Weichai Gen set are used to remind operators and maintenance personnel of the fact that serious personal injuries or significant property losses would be caused if they do not follow these warnings Meanings that these safety symbols express are as shown in Table
25. power parameters of alternator kVA kW PF kVAR kWh kVAH and kVARH parameters of mains power frequency three phase voltage L L and L N contains 12 inputs and 8 outputs 8 inputs and 4 outputs can be customized and sets programs by panel or software Display content and input output port of DSE7320 display module of the Gen set with different configuration may be different slightly 22 Diesel Gen set Operation Instructions pag DEEP SEA ah e Gen set stop and fault resetting button Gen set manual mode button Mains power fault simulation and test button Gen set AUTO mode button 23 LED indicator light Diesel Gen set Operation Instructions Silence button Gen set start button operative under manual mode Alternator switching on button Mains power switching on button applicable for the case when AMF function is used Enter button Left and right menu navigation button used to select menu in turn Up and down selection button used to query parameters in each menu in turn 12 When generated electricity Gen set operates normally exists green light turns on 13 When generated electricity the Gen set supplies power to loads is switched on green light turns on 14 When mains power usage of AMF function 1s available exists green light turns on 24 Diesel Gen set Operation Instructions 15 When mains power mains power system supplies power to loads which is
26. shall not be grounded Restart the Gen set and record output voltage of main stator which shall be close to rated voltage or voltage between terminals below of AVR shall be 170 250V AS440 and AS480 terminal 7 8 SE350 terminal 3 4 Stop the Gen set Disconnect the battery from terminals Fl and F2 if AS440 KRS440 or AS480 is used or terminal F and F 1f SE350 and BE350 1s used Restart the Gen set the alternator shall run normally If there 1s no voltage the alternator or AVR line may have problems Please inspect the winding rotating diode and AVR of Gen set according to procedures of excitation separation test 5 2 Under Frequency Roll Off UFRO AVR is connected to an under frequency protective circuit Its voltage frequency characteristic 1s shown in Figure 10 2 Clockwise regulation ue Clockwise regulation Knee poin gt of curve a Voltage _ Droop is typical setting 90 as shown in the figure 85 80 75 80 85 90 95 100 9cFrequency Hz Figure 10 2 Characteristic of UFRO low frequency protection UFRO control potentiometer 1s used to set the knee point Inappropriate setting will lead to the following consequences A light emitting diode LED on the top of UFRO control potentiometer is on with load Voltage regulation factor is low with load 1 e the alternator operation curve falls on the oblique line of characteristic curve Clockwise rotation will reduce frequency at kn
27. voltage of main stator armature By constant cycling of this voltage buildup process alternator builds up rated voltage steadily n a short time Diesel Gen set Operation Instructions Permanent magnet alternator Rotating part Three phase alternating optional e current output E Permanent magnet rotor rotor t Excitation rotor mn nae Excitation stator armature ee ne Main stator armature magnetic field s Permanent magnet Three phase alternating Main rotor magnetic 008 alternator armature current output field Rotary rectifier three phase full wave rectifier l Excitation field direct p Detection input regulator AVR E output Automatic voltage EE 1 Input signal single item voltage regulator input power Figure 3 3 Alternator operating principles schematic diagram 3 Automatic voltage regulator AVR AVR of Weichai alternator is a half wave phased thyratron type automatic voltage regulator and one part of alternating current brushless alternator excitation system Except regulating voltage of alternator AVR 1s equipped with low speed and no detection signal protection function in order to ensure that alternator is controlled in a safe and reliable way Weichai 20 120kW Gen set is equipped with AS440 BE350 AS480 or KRS440 type AVR type of AVR is clearly marked on nameplate of alternator Struct
28. Able to support total wet weight of Gen set including the Gen set accessory equipment coolant lubricating oil and diesel oil etc 2 Able to withstand periodic vibration during operation of the Gen set It is recommended that customers cast a concrete foundation as per following design principles 1 Overall dimensions of the foundation must at least 300mm larger than that of Gen set 2 Height of foundation shall be calculated as per following formula FD 2W DxBxL Wherein FD foundation height m 36 Diesel Alternator Set Operation Instructions W total wet weight of the Gen set kg D density of concrete kg m3 2 402 8 kg m3 L length of foundation m F width of foundation m Suggestion dimensions of foundation for 20 30kW Gen set 40 75kW Gen set and 90 120kW Gen set are 2820mm L x1500mm W x200mm H 3200mm L x1500mm W x200mm H and 3650mm L x1500mm W x200mm H respectively 3 Transportation of the Gen set Common chassis of Weichai Gen set is designed with lifting eye and forklift groove and the Gen set can be transported and installed by using crane or forklift When crane is used in order to prevent the Gen set from being titled when being lifted up four steel wire ropes whose length is the same shall be used In addition these steel wire ropes shall have enough strength and carrying capacity of lifting tools shall meet requirements of safety specifications When being lifted the G
29. OPERATION eene 58 IL XOPBEATION OE THE GENSSET Her une 59 Chapter 9 Maintenance and Care of the Gen set eene 64 I MAINTENANCE AND CARE SCHEDULE cscscssesceassconsesconscceaeseoaescancsceneescenseces 64 II MAINTENANCE AND CARE OPERATION eee enne nnne nnne nennen nnns 65 Chapter 10 Common Failures and Troubleshooting eeeeeeeesssssss 75 Chapter 11 Service COPIBUTDEL are 92 l SERVICE CONC PW ee nee 92 I SERVICE GCOMMILEMEN I 45535 92 III PRINCIPLE AND PROVISION OF QUALITY WARRANTY THREE GUARANTEES essen 92 Diesel Gen set Operation Instructions Chapter 1 Safety I Safety rules Before starting the Gen set be sure to read this Operation Manual carefully and know this equipment well The purpose of safe and effective operation can be realized only if the equipment is operated and maintained correctly Occurrence of many accidental injuries often s caused by the reason that basic safety rules are not observed The Gen set equipment must be operated only by trained electricians The following rules are provided to remind operators and maintenance personnel of the danger situations that may occur 1 Electric shock may cause injuries of operators 1 1 Casing of Gen set must be grounded in order to prevent endangerment to personal safety of operators caused by live casing Because Weichai Gen set 1s designed with safe grounding system customers on
30. Operation amp Maintains Manual of Weichai Group Diesel Gen set Version No V01 Weichai Heavy Machinery Co Ltd Foreword Before operating the Gen set please read this Operation Manual carefully This user manual is mainly used to guide customers how to use this equipment describes structural composition operation and use daily maintenance and care fault diagnosis and measures that shall be taken n details is helpful for operators and maintenance personnel to use and maintain the Gen set correctly and contributes for judgment analysis and troubleshooting when the Gen set malfunctions in order to ensure that the equipment can be put into normal operation rapidly Please refer to and read diesel engine s operation manual alternator s user manual and drawings and documents of control part etc provided with the Gen set whiling reading this manual in order to prevent accidental operations and misjudgment on faults Precautions in this manual are basic principles that the operators must follow and perform strictly The purpose of safe and effective operation can be realized only if the equipment is operated and maintained correctly Occurrence of many accidental injuries often is caused by the reason that basic safety rules are not observed Contents Chapter Sale Desaster l oS EE DX RUDPBS ee ee 1 ESATE SYMBOLS u era 2 Chapter 2 Operating Conditions and Purposes of the Gen set nnen 5 I DESCRIP
31. TION ON MODEL OF THE GEN SET eene nennen nnne nnns 5 II DESCRIPTION ON POWER OF THE GEN SET eeeeeeee eene nnne nnn nnne nnns 5 III ENVIRONMENT ADAPTABILITY OF THE GEN SET eene nnne 6 IV POWER CORRECTION OF THE GENGCSET cccccsssscccceessececceeseeecseuseeeeseaseseeeeas 6 VARANGER OP APPLICATION ses asien 7 Chapter 3 Overview on Main Structure of the Gen set ucessssssssssssseeeeeennnnennennnnn 8 1SDIESELENGINE u energie 8 TEATER NATO ae ER ernennen 8 IEC ONTROL PANEL ae 18 Chapter 4 Main Specifications and Technical Parameters of the Gen set 31 Chapter 5 Transportation ofthe Gen set ai roe onde EET ES sd vddh 34 Chapter 6 Installation of the Gen Set cccccccccccccccccceceeceaeeeeeeeeseeeeeeeeeeeeeeseeeeeeaaaaas 35 I PREPARATIONS BEFORE INSTALLATION cssccsssccssscenssscoasescasssdensscesescensceenesses 35 II REQUIREMENTS FOR INSTALLATION OF THE GEN SET eene 35 III STANDARD EQUIPMENT ROOM ARRANGEMENT OF THE GEN SET 45 Chapter 7 Commissioning of the Gen Set cccccccccccccccceceeeeeeeaeeseeeessseseeeeeeeeeeeeees 46 I INSPECTIONS BEFORE COMMISSIONING ccecccceccececcececcccecceteccecesteccstecceeecees 46 II PREPARATIONS BEFORE COMMISSIONING eee eene 47 I COMMISSIONING OF THE GENESE D ansteigt 53 Chapter 8 Operation Or the Gen set een ee 58 I PREPARATIONS AND INSPECTIONS BEFORE
32. VA Weichai Power Generation II Description on power of the Gen set 1 Rated power it refers to the maximum power that the Gen set is able to provide continuous power supply to variable loads without limitation in annual running time between specified maintenance intervals and under specified environmental conditions Its allowable average output power in an interval of 24h shall not be greater than 70 of rated power An interval of Ih overload power supply is allowable in every 12h operation of Weichai Gen set and its overload capacity is 10 of rated output power 5 Diesel Gen set Operation Instructions 2 Rated capacity for the Gen set whose power factor is 0 8 lagging its rated capacity shall be 1 25 times of rated power 3 Reserve capacity reserve capacity of Weichai Gen set is 1 1 times of rated capacity III Environment adaptability of the Gen set Under following environmental conditions the Gen set shall be able to operate normally and output rated power gt Ambient temperature 25 C Range of altitude 0 1000m gt Relative air humidity 30 60 Under non standard environmental conditions the Gen set shall be able to operate normally But rated power of the Gen set must be corrected IV Power correction of the Gen set When the Gen set is going to operate under non standard environmental conditions rated power of the Gen set shall be corrected If the load power of the Gen set dur
33. afety protections during transportation The wooden carrying case standard configuration of Weichai Gen set can prevent the Gen set from being suffered from damages caused by external shocks effectively In addition the Gen set shall be firmly secured during transportation n order to prevent loosening or damage of parts caused by vibration When loading or unloading the Gen set onto or from the vehicle use a crane to lift up the Gen set n a balanced way n order to avoid damage of the Gen set caused by tilting or falling to the ground 34 Diesel Alternator Set Operation Instructions Chapter 6 Installation of the Gen set I Preparations before installation 1 Unpacking of the Gen set Before unpacking clean dust and check 1f body of the case is damaged or not at first Then check case number and quantity and do not damage the machine during unpacking During unpacking top plate shall be removed first and side plates shall be removed latter Followings are necessary after unpacking 1 Checking of Gen set nameplate and checking 1f the Gen set meets ordering requirements or not 2 Making an inventory on the Gen set and its accessories in accordance with packing list of the Gen set 3 Checking f the Gen set and its accessories are damaged or rusted or not The Gen set after being unpacked must be positioned horizontally and flanges and various joints must be sealed in order to prevent intrusion of mo
34. and connected to breaker of the Gen set with flexible cable Power cable of the Gen set shall be selected as per carrying capacity of cable 42 Diesel Alternator Set Operation Instructions while carrying capacity of cable is relative to both cross section of it and material type and laying method of cable as well as ambient temperature In addition influence factors are many and calculation is complex also Weichai recommends you to select cable as per following specifications Table 6 1 Specifications of power cable of the Gen set Specifications of copper core insulated Power of the Gen set kW l cable E area mm2 23204 0 24 8 2 Laying of power cable Shortest routing minimum turns laying and maintenance convenience shall be followed during laying cable in order to prevent cables from being damaged mechanically or chemically or by earth current and other factors Selection of cable laying method depends on engineering conditions environmental characteristics cable type and quantity and other factors and shall be carried out by adhering to the principles of reliable operation ease of maintenance and economic and reasonable technology Cable laying 1s divided into underground direct burial laying protection conduit laying cable trench laying tunnel laying underwater laying and laying along the wall etc Selection of cable laying method depends on engineering conditions environmental characteristics cabl
35. appropriate trademark E Clean intake manifold and air filter and 3 Air intake system is blocked replace them if necessary Clear the carbon deposit in exhaust 4 Exhaust back pressure is too high l manifold and silencer Turbocharger is dirty Clean the turbocharger l Inspect and replace fuel filter sealing Oil supply system is blocked l gasket and oil supply line Find out the leaking point for repair and d Oil supply system leaks replacement ee Contact with after sales service personnel Fault of injection pump to recalibrate or replace 8 Lubricating oil consumption is too high Serial RE Cause Elimination method number Wrong lubricating oil trademark Use lubricating oil of correct trademark Piston ring piston or cylinder liner suffers l Replace piston ring piston or cylinder 2 from serious wear and tear which makes i iner machine oil enter combustion chamber Valve rod and guide suffer from serious wear and tear which makes machine oil Replace valve rod and guide enter combustion chamber There is too much machine oil in oil pan 4 which makes machine oil enter Discharge surplus machine oil combustion chamber 9 The Gen set can not be stopped Serial TS Cause Elimination method number Eliminate any open circuit poor contact Poor contact open circuit inspect whether the contact suffers from oxidation and clean it if necessary Fault of wiring of key switch Inspect wi
36. be removed with proper methods and all parts lubricating oil line fuel system and supercharger etc treated with protective agent shall be cleaned completely Protection procedures of the Gen set are as follows 1 After the Gen set is warmed up clean engine oil filter and add anti rust oil to oil pan of diesel engine 2 Drain all diesel oil in fuel system and fill a mixture of 90 diesel oil and 10 anti rust oil to protect the entire fuel lines The mixture must be mixed fully before being filled 3 If the diesel engine is not filled with cooling emulsion fill cooling emulsion and anti rust oil protecting cooling jacket after cooling water is drained Before sealing up and after filling of above emulsion start the Gen set as per starting procedures and let 1s idle for 15 25 minutes 4 Remove cover plate on short face of intake pipe spray anti rust oil to intake pipe with a pressure nozzle Rotate crankshaft with hand when spraying oil in order to open air valve and let anti rust oil flow into combustion chamber Do not rotate crankshaft anymore once all sealing up works are completed in order to prevent oil film attached on cylinder wall from being scratched off 5 Drain various oils and fluids in diesel engine drain or pump anti rust oil from engine base drain emulsion from cooling system and keep all draining switches open 6 Remove rocker arm cover to spray anti rust oil to valve spring and rocker arm 7
37. blocked o manifold and replace it if necessary i Clear carbon deposit in the silencer and Silencer is blocked ee replace it if necessary The temperature of diesel engine is too high which reduces aeration rate of Inspect operation of cooling system and cylinder and makes combustion repair incomplete a Clean the lubrication system and Viscosity of machine is too high which a replace the machine oil with that of 10 increases running resistance of diesel l appropriate trademark as required in engine and power consumption f instructions Resistance of crankshaft dipped in Discharge surplus machine oil to make 11 machine oil is great due to too much machine oil level in oil pan between machine oil in oil pan high and low levels of dipstick Exhaust gas turbocharger is blocked or Clean exhaust gas turbocharger and DEM impeller is damaged replace it if necessary Compression pressure of cylinder is l 13 l l Replace the piston ring insufficient due to piston ring scuffing Contact with after sales service seal leakage of intake exhaust valve personnel to repair or replace Contact with after sales service difficult for the valve to return personnel to repair or replace Cylinder gasket is damaged causing air 17 leakage of joint surface between cylinder Replace the cylinder gasket head and engine body Contact with after sales service 18 Fuel supply advance angle is inaccurate VN pers
38. ch on knocking sound of metal in the cylinder which is increasing the load so knocking sound is made due and load the Gen set after it to too big clearance between piston and cylinder changes into hot state in idle liner running Knocking sound is made due to too serious wear Replace the corresponding and tear of piston piston ring and cylinder liner part Knocking sound can be heard along the whole engine body due to too serious wear and tear of Repair or replace the bearing journals and bearing bushes of crankshaft The valve hits the top of piston due to too small Adjust valve clearance or clearance of intake exhaust valve or incorrect timing D iming of intake exhaust y Individual cylinder doesn t work to intensify Inspect fuel system and vibration of diesel engine troubleshoot 4 Valve is broken sudden and violent crash is made due to damage to valve lock clamp falling of valve Immediately stop for overhaul or breakage of piston Inspect bolt pretightening force Squealing of air leakage is made at cylinder head of cylinder head and replace gasket the cylinder gasket if necessary Knocking sound due to too serious wear and tear of Inspect and replace them gears Fixing bolt of the diesel engine is loose or damaged a PU Tighten or replace the bolt which intensifies vibration E TN Inspect whether chassis is Diesel engine is not concentric with alternator MEN i deformed and shock abso
39. cing the damaged parts for free if the Gen set is damaged due to poor manufacturing and record is available within 12 months after leaving the factory or 1500h after being put into operation accumulatively Our company will not compensate for machine faults caused by improper use But we can provide users with paid technical service and parts to help them promptly solve the problems
40. device to prevent 41 Diesel Alternator Set Operation Instructions fire caused by internal electrostatic spark generated during refueling 7 2 Fuel delivery pipe 1 Diameter of fuel pipe depends on inlet diameter of fuel injection pump and shall be the same with inner diameter of inlet at least f it 1s far in distance diameter of the pipe shall be increased properly n general outlet of daily used fuel tank shall be provided with an auxiliary fuel pump in order to avoid excess siphon pressure from being produced in the pipe 2 Connection between pipe and the Gen set shall be flexible and close to fuel pump of the Gen set as much as possible 3 Exposed sections of the pipe shall be supported and protected properly in order to prevent them from being damaged 4 The pipe shall be kept away from high temperature parts such as hot pipes stove electric wires exhaust pipe etc If ambient temperature is relatively high proper heat insulation measures shall be taken 5 After the pipe is installed clean it and check if there is any leakage as well as bleed air in the pipe 6 The part where fuel return pipe enters into daily use fuel tank shall be higher than the maximum fuel level 8 Power cable 8 1 Power cable selection Connecting cable between breaker of the Gen set and loads shall be flexible If flexible cable is unavailable due to installation limitations a junction box shall be provided near the Gen set
41. diesel engine is governed electronically and it 1s necessary to adjust speed open throttle body of control panel and adjust speed fine adjusting positioner 2 Check voltage of three phase output line of the Gen set Voltage of each line shall be 400V 3 Check three phase current of the Gen set by ampere meter and three phase current change over switch and the measured current value shall not exceed rated current of the Gen set 4 Check 1f water temperature and oil pressure of the Gen set is normal or not Water temperature shall not be lower than 95 C and oil pressure shall be higher than 0 15Mpa 56 Diesel Alternator Set Operation Instructions 5 Check if belched smoke is normal Belched smoke of the Gen set shall be colorless It is abnormal if large amount of black smoke blue smoke or white smoke is belched from this diesel engine Note never increase load rapidly when coolant temperature is not higher than 60 C 3 Stop capacity 3 1 Normal stop 1 Remove loads at first proceed to switching off operation and let the Gen set operate without load for 3 5 minutes after being unloaded 2 Press stop button e stop electromagnet operates pull stop handle to stop position to stop operation of the Gen set 3 Finally turn power switch to OFF position to cut off power supply of the entire control system 4 Remove connecting cable from negative electrode of battery and protect it with insulation tape 3 2
42. e as follows 1 Check speed and frequency of the Gen set normal speed and frequency of the Gen set 1s separately 1530 1560r min and 51 52Hz 2 Check three phase output voltage of the Gen set and the value shall be 400V 3 Check current of the Gen set and this current shall not exceed rated current of the Gen set 4 Check 1f water temperature and oil pressure of the Gen set is normal or not Water temperature shall be lower than 95 C and oil pressure shall be higher than 0 15Mpa 5 Check f belched smoke s normal Belched smoke of the Gen set shall be colorless It is abnormal if large amount of black smoke blue smoke or white smoke is belched from this diesel engine Note it is necessary to check operation state of the Gen set every 1 hour Note be sure to switch on air switch under supervision of power 60 Diesel Alternator Set Operation Instructions distribution personnel only after confirming that electric equipment can be powered by the Gen set Note make sure that load does not exceed rated power of the Gen set Note be sure that the Gen set is not operated under no load state continuously for more than 30 minutes in order to prevent leakage of lubricating oil of the Gen set Warning do not try to touch exhaust pipe turbocharger high temperature coolant amp heater and other high temperature surfaces of the Gen set with your hands when the Gen set is operating or your hands would be burnt War
43. e type and quantity and other factors and shall be carried out by adhering to the principles of reliable operation ease of maintenance and economic and reasonable technology For laying method of power cable please refer to GF 50217 2007 Code for Design of Cables for Electric Power Project 9 Grounding 43 Diesel Alternator Set Operation Instructions Grounding of electrical system must be taken into consideration during installation of Gen set in order to prevent insulation of electrical equipment on the Gen set from being damaged or prevent electric shock personal injuries or even death caused by electrification of exposed current carrying part which is usually not live when any leakage current is produced Besides casing of the Gen set shall be grounded in order to provide personnel protection for operators In order to improve reliability of electricity utilization neutral point grounding generally is not recommended It will not cause an accident when one phase of ungrounded power supply system is grounded And operation will not be influenced when there is no voltage between only this phase and ground No accident will be caused if this can be discovered timely if above phenomenon occurs in the power supply system in which only the neutral point is grounded it would cause tripping and striking of sparks at grounding point or even gas explosion Warning incorrect grounding would cause personal injuries or even death
44. ect power of the Gen set according to change of environmental conditions For details of correction factor please consult Weichai Power Generation Equipment Co Ltd V Range of application At present diesel Gen set has been widely used in aviation shipping national defense communication petroleum medical treatment mining wild rescue agriculture and animal husbandry as well as other fields to ensure reliability and stability of power supply system Diesel Gen set Operation Instructions Chapter 3 Overview on Main Structure of the Gen set pa HEC Li Mi ee tt 4 1 gt 3 4 5 6 i 8 M l Air inlet 2 Chassis 3 Alternator 4 Forklift groove 5 Batteries 6 Oil drain hole 7 Fuel level indicator 8 Radiator 9 Silencer 10 Exhaust chamber 12 Air filter 13 Control panel 11 Inlet of fuel delivery pump Fig 3 1 Structural schematic diagram of the Gen set The Gen set mainly consists of diesel engine alternator control panel low noise shed body and chassis etc Detail structure of the Gen set 1s as shown in Figure 3 1 Main parts of the Gen set will be detailed below I Diesel engine Diesel engine is power source of the Gen set For detail structure and principles please refer to Diesel Engine Operation and Maintenance Manual II Alternator Alternator 1s a device converting mechanical energy into electrical energy Diesel Gen set Operation Instructions 1 Structure of alternator The We
45. ed by these dust and pollutants 6 Check if electrodes of battery are corroded or not If any clean it 7 Check restriction indicator of air filter and replace the filter if restriction display appears 8 Check level of fuel engine oil and coolant in the Gen set Carry out refilling when the level is low 9 Check if all pipelines and joints in fuel supply system lubrication system cooling system and other systems of diesel engine are free from fuel leakage and water leakage 58 Diesel Alternator Set Operation Instructions 10 Make sure that air switch of the Gen set 1s OFF 11 Connect negative battery cable II Operation of the Gen set 1 Starting of the Gen set Turn power switch on control panel to ON position at first and display module of control panel s able to display various parameters normally then stop electromagnet operates and push stop handle to fuel supply position Press manual mode button and indicator light turns on when manual mode is switched to After the controller is in manual mode press g start button again to start the Gen set Check if the Gen set operates normally or not and then press stop button SA the Gen set will stop after operation without load at rated speed for 120s If you want to stop the Gen set directly press stop button two times directly Note do not start the Gen set when being loaded namely air switch shall be in switching off position when the Gen se
46. ee point and turn off light emitting diode The optimal setting should ensure that when frequency is below the normal range 1 e frequency of 50Hz alternator is 47Hz and that of 60Hz alternator is 57Hz the indicator light will be on 5 3 Procedures of Excitation Separation Test Inspect winding rotating diode and AVR of alternator in the corresponding procedure below Disconnect wires Fl and F2 or F and F of excitation stator magnetic field from AVR and supply power to Fl and F2 or F and F with a 12V DC power source Start the Gen set and operate at rated speed Measure voltage at primary output terminals U V and W 5 3 1 Voltage Balance of Primary Output Terminal 1 If the measured voltage is generally balanced with the unbalance index within 1 and within 10 of rated voltage of alternator all excitation windings main windings and main rotating diodes are sound and AVR or transformer control may have problems Test AVR according to the following procedures 2 Remove lead of magnetic field from terminals F1 and F2 or F and F of AVR 3 Connect a 60W 240V bulb between terminals Fl and F2 or F and F of AVR 4 Rotate voltage control potentiometer on AVR clockwise to the end 5 Connect 12V1 0A DC power source to Fl and F2 or F and F of lead of magnetic field Note that positive electrode is connected to Fl F 6 Start the Gen set and operate at rated speed 7 Inspect whether the deviation
47. electric circuits to see if wiring harness is damaged or leaks electricity or not If any replace the wire and check if the connection is loose or damaged or not If any tighten or replace it 4 Check reliability of fasteners and throttle control system confirm 1f various operating mechanisms are flexible portable and reliable and check pre tensioning of charger belt and fan belt 5 Check if there is large amount of dust accumulating on control panel and Gen set If any clean it in order to prevent electric shock or reduction of cooling performance of the Gen set caused by these dust and impurities 6 Check if electrodes of battery are corroded or not If any clean it Check voltage of battery if it is less than 9V 12V system or 19V 24V system and does not meet starting requirements charge the battery Warning do not place wrench iron pipe or conductors on battery because this is easy to cause short connection of positive and negative electrode of battery and accidents 46 Diesel Alternator Set Operation Instructions Danger when cleaning battery do not smoke or carry out fire related works nearby because the hydrogen generated during electrolysis of battery may cause an explosion 7 Check restriction indicator of air filter and clean the filter if restriction display appears 8 Check if air switch of the Gen set 1s off II Preparations before commissioning 1 Refilling of coolant 1 1 Coolant selec
48. ell and short connection 1s 52 Diesel Alternator Set Operation Instructions prohibited 4 Air switch 1s in switching off state 6 Testing insulation resistance 1 Open outlet box cover plate of alternator to remove wiring on main stator armature of alternator AVR namely No 7 and No 8 wiring of AS440 and AS480 for SE350 remove No 3 and No 4 wiring 2 Disconnect grounding conductors between all neutral wires and grounding wires 3 Measure insulation resistance to ground of leading out terminal U V and W in turn with a 500V mega ohm meter or other similar instruments 4 Measure insulation resistance to ground of excitation stator magnetic field namely insulation resistance to ground of Fl and F2 wiring on AS440 and AS480 for SE350 measure insulation resistance to ground of F and F 5 The resistance value shall be greater than 5MQ If not be sure to dry the coil by referring to the drying method specified in Chapter 9 7 Connecting negative battery cable Connect negative battery cable to battery and protect it with insulation protection cap III Commissioning of the Gen set 1 Start capacity Turn power switch on control panel to ON position at first and the control panel display module shall be able to display normally for mechanically governing diesel engine stop electromagnet operates to turn stop handle to fuel supply position observe battery voltage from display screen and connect
49. en set shall be kept horizontal and lifted slowly in order to prevent the Gen set from swinging and prevent steel wire ropes from tied during lifting When using forklift be sure to hold up the Gen set slowly or carefully push or pull from base of the Gen set Note parts of the Gen set would be seriously damaged if incorrect transportation method is adopted Note do not lift up the Gen set from lifting eyes on diesel engine or alternator 37 Diesel Alternator Set Operation Instructions Note check if suspension equipment and supports are in good conditions and if load weight of suspension equipment is proper Note for outdoor lifting do not lift up the Gen set in heavy windy days Warning all people shall be kept away from lifted Gen set 4 Installation of the Gen set The Gen set shall be connected to foundation with anchor bolts or proper cushions Fixing chassis of the Gen set to foundation with anchor bolts can not only reduce vibration effectively but also can prevent moving of the Gen set Therefore damage of the components on the Gen set caused by vibration can be avoided also Alternatively you can add proper number of anti vibration pads between chassis of the Gen set and foundation because these anti vibration pads can not only make up fine unevenness of ground but also increase resistance between the Gen set and ground and improve cushioning function Suggestion fix with anchor bolts because
50. ensure safety of personnel travelling across the ground and prevent accidental contact 6 4 Owning to the fact that temperature of exhaust pipe is high in order to prevent burns and prevent rising of temperature in equipment room caused by radiant heat heat insulation treatment shall be carried out And heat insulation materials shall be wrapped with glass fiber or aluminum silicate effective for heat insulation and noise reduction In addition exhaust terminal and exposed part of exhaust pipe shall be kept away from woods or other flammable substances 6 5 Exhaust terminal shall be able to avoid dropping of rain water The exhaust pipe can be projected horizontally and chamfered at end to an angle of 30 45 In order to prevent rain water and condensed fluid flows backward to the Gen set The exhaust pipe placed horizontally shall be titled to some angle low end of it shall be kept away from engine silencer and any section of the pipe where condensed liquid exists e g vertical turn of exhaust pipe shall be equipped with outlet 6 6 Position of exhaust outlet shall be designed as per following principles 40 Diesel Alternator Set Operation Instructions 1 Keep away from air intake 2 Reduce noise impacts on environment 3 Avoid dust generated in exhausting from accumulating on adjacent buildings 7 Fuel supply system Daily use fuel tank and fuel pipelines shall be provided to this series of Gen set according to spec
51. es of above insulation resistances are values measured when temperature of winding is 20 C If insulation resistance 1s still lower than IMQ after above drying process carry out polarization test of coil If all parts cannot meet the requirement of IMQ insulation resistance wind the coil again or clean alternator again Never put the alternator into service when minimum insulation resistance requirement is not met Measurement of insulation resistance shall be carried again after winding is dried up in order to ensure that the above minimum resistance requirement can be met 7 Cleaning method of air filter on alternator Warning live parts would be contacted when removing parts of air filter so removal of these parts is allowable only after stopping Remove parts of air filter from air filter cover and soak or wash these parts with proper oil removal agent until these parts are fully cleaned In addition dry these parts fully before being reinstalled Maintenance of the Gen set The engine and AC alternator would be damaged when the Gen set 1s not used for a long period of time Correct storage of the Gen set may reduce this damage to the minimum 8 1 It is the optimal if the Gen set is placed in an environment in which ambient temperature is 20 C 25 C relative humidity is 2096 7096 and air pressure is 70kPa 106kPa 73 Diesel Alternator Set Operation Instructions 8 2 Before sealing up all rusts shall
52. g wire of SE350 of excitation stator magnetic field on AVR Add a direct current electrical source between the disconnected two conductors connect Fl or F to positive electrode and connect F2 or F to negative electrode and this direct current electrical source must be adjustable in a range of 0 24V and s able to provide 2 0A current to an extreme Connect a proper AC ammeter to measure short circuit current Adjust voltage of direct current power source to zero at first and then start the Gen set Increase direct current voltage slowly so as that current flows in coil of excitation stator magnetic field When excitation current increases the stator current in short circuit state will increase also Be sure to measure current of stator so as that it is not 80 higher than rated current Please perform following measurements every 30 minutes Stop the Gen set disconnect externally connected exciting DC power source and then measure record and tabulate insulation resistance of stator coil The measured figure shall be compared with typical curve and the drying process will be completed when insulation resistance reaches to the value specified in typical drying curve Once the insulation resistance reaches to IMQ remove the DC power source and reconnect magnetic field lead of exciter F1 and F2 connecting wire of AS440 71 Diesel Alternator Set Operation Instructions and AS480 F and F connecting wire of SE350 t
53. he winding of main rotor is connected to two rectifying plates Corresponding lead must be disconnected before reading 5 3 2 Voltage Imbalance of Primary Output Terminal Voltage imbalance shows that main stator winding or main cable connected to circuit breaker may have problems Note during excitation fault of stator winding and main cable may significantly increase the load of engine Disconnect the main cable and leads of winding U1 U2 U5 U6 V1 V2 V5 V6 W1 W2 W5 W6 to separate the windings Measure phase to phase and phase to ground insulation resistance Imbalanced or incorrect winding resistance and or too low insulation resistance to ground indicates that stator coil must be replaced 1 Insufficient output power of Gen set Serial TP Cause Elimination method number Combustion of combustible mixture is Normal phenomenon The diesel engine affected in cold state of diesel engine can only be loaded in hot state A Load power is more than rated power of Reduce load or select Gen set of higher Gen set rated power 3 Air is thin due to too high temperature or Consult salesmen about correcting altitude power of Gen set as Find out the fault point to repair or 4 Air leakage of air intake system replace Clean intake manifold and replace it if 5 Intake manifold is blocked necessary Clean air filter and replace it if Fault of air filter necessary ae Clear carbon deposit in the exhaust 7 Exhaust pipe is
54. ichai Gen set adopts a brushless three phase synchronous alternator As shown in Figure 3 2 the alternator mainly consists of main stator armature main rotor magnetic field exciter stator magnetic field exciter rotor armature rotary rectifier automatic voltage regulator AVR and outlet box etc Stator alternatin f i Main stator armature Main rotor current output magnetic field Rotary rectifier N v Coupling Optional permanent N v magnet alternator ii E Se ae e pe E g ay om p du et In Gili 2 He we aH Zi Permanent magnet M u ZisEB SL alternator rotor d i magnetic field BENE LIENS dip 7 dae _ all Permanent magnet Sen stator armature J Bearing Exciter stator Gener field Exciter rotor armature Installation of coupling Figure 3 2 Sectional view of alternator 2 Operating principles of alternator After alternator is driven main stator armature generates certain remanence voltage automatic voltage regulator AVR outputs a remanence current to exciter stator magnetic field after obtaining remanence voltage from main stator armature exciter rotor armature generates three phase alternating current which is then transmitted to main rotor magnetic field excitation winding after being rectified into direct current by rotary rectifier n order to enhance magnetic field of main rotor and increase
55. ific circumstances to supply fuel to the Gen set 7 1 Daily use fuel tank 1 Fuel capacity of standard configured chassis fuel tank provided for low noise series Gen set can meet 8h operation demand of the Gen set 1f the Gen set is used as a daily power source you d better select a daily use fuel tank with proper capacity meeting 24h continuous operation of the Gen set under rated load Suggestion it is recommended to select 180L daily use fuel tank for 20 30kW Gen set 300L daily use fuel tank for 40 50kW Gen set 450L daily use fuel tank for 64 75kW Gen set and 720L daily use fuel tank for 90 120kW Gen set 2 The daily used fuel tank shall be installed at a place which it is convenient for refueling and not far away from the Gen set Except refilling oil to daily use fuel tank manually it is acceptable to refill fuel to daily use fuel tank by a manual pump or automatic refueling system 3 Outlet of daily used fuel tank shall be at a position which is 0 5m above foundation of the Gen set the same with height of fuel injection pump of diesel engine The outlet shall not be too high not Im higher than fuel injection pump in order to avoid its pressure from exceeding maximum pressure resistance of fuel pump of the Gen set and it shall not be too low not 0 5m lower than fuel injection pump in order to prevent it from exceeding suction range of fuel injection pump 4 The daily used fuel tank shall be equipped with grounding
56. il information of current page Stop operation of Gen set 20 2 Power switch Diesel Gen set Operation Instructions Press this button to enter into manual mode and adjust parameters Simulate state of loss of mains power and adjust parameters Press this button to enter into AUTO mode Silence button Start Gen set Alarm indication light the module will record the latest 5 alarm records for ease of maintenance Control power on off of control panel of the Gen set 3 Emergency stop button Press this button to stop the Gen set immediately when any emergency occurs And the Gen set is unable to be started under this state When the emergency situation 1s over the Gen set can be started only after emergency stop button is released 4 Air switch Except closing and opening of circuit it is still available for short circuit and 21 Diesel Gen set Operation Instructions serious overload protection of circuits or electrical equipment Structure of the control panel of DSE7320 module 1s as shown in Figure 3 10 DSE7320 module Power switch Air switch Figure 3 10 Control panel drawing 1 DSE7320 display module 7320 module of Deep Sea Electronics is an AMF ATS module which is able to display various parameters of engine speed oil pressure water temperature fuel level and battery voltage parameters of alternator frequency three phase voltage L L and L N and current
57. in the following way mix 0 5kg soda with 20 liter water fill the solution into water tank of radiator and then drain it to its original container 8 After multiple flushing of above keep water tank of radiator fully with water for at least hour and then drain water in it Finally flush water tank of radiator again with fresh hot water 9 When reusing the radiator fill water tank with water and carry out pressure test at a pressure which is two times of operating pressure then carefully check if there 1s any leakage caused by rusty scale 10 Before commissioning once again mix coolant with necessary anti rust and 69 Diesel Alternator Set Operation Instructions anti corrosion agents or anti freeze of proper proportion 6 Drying of alternator 6 1 Cold state operation If a normal alternator 1s left out of operation for a long period of time in a dusty and moisture environment simply operate the Gen set with connecting wire Fl and F2 connecting wire of AS440 and AS480 F and F connecting wire of SE350 of excitation stator magnetic field of AVR is disconnected for 10 minutes or longer Just by this the requirement to dry winding surface and increase insulation resistance value to 1 MQ or higher so as that the Gen set can be used for normal operation directly can be met 6 2 Drying by introducing air Remove all cover plates on alternator in order that moist air can run away During the process of drying air strea
58. inder head piston combustion chamber and cylinder jacket II Maintenance and care operation 1 Checking fuel engine oil and coolant level Fuel level never operate the Gen set when fuel level is lower than lower scale mark Fill proper amount of diesel oil into chassis fuel tank or daily use fuel tank Engine oil level as shown in Figure 9 1 never operate the Gen set when engine oil level is lower than L low level scale mark or higher than H high level scale mark When engine oil level is lower than L low level scale mark fill engine oil of the same grade until the level is between L and H scale marks when engine oil level is higher than H high level scale mark drain proper amount of engine oil until the level is between L and H scale mark HER Oil dipstick 65 Diesel Alternator Set Operation Instructions Figure 9 1 Engine oil level Coolant level when coolant level is low fill proper amount of coolant into water tank until coolant level in radiator is 5cm below filler 2 Replacing engine oil and oil filter element Replacement is necessary after first 50 hours operation of the Gen set Then replacement is necessary every 200h operation as per following specific procedures 2 1 Start the Gen set until water temperature reaches to 60 C Then stop the Gen set and prepare a vessel to collect drained engine oil Immediately open oil drain valve on oil pan to drain engine oil and impurities fully dur
59. ing operation 1s greater than corrected rated power the diesel engine will belch a lots of black smoke and become overheating If operation like this 1s kept for a long period of time diesel engine will malfunction seriously or be damaged so this situation must be avoided When ambient temperature is extremely high air density would decrease amount of oxygen provided during combustion of diesel engine will decrease As combustion efficiency reduces and mechanical output power of diesel engine will reduce accordingly at the same time winding needs to be cooled by air during operation of alternator thus cooling performance will decrease and internal temperature of alternator winding will raise when ambient temperature 1s extremely high Therefore in order to ensure that temperature of alternator winding is kept 6 Diesel Gen set Operation Instructions within an allowable range output power of alternator must be reduced Air density will decrease also when the altitude increases thus output of diesel engine and alternator will be affected also Although output power of diesel Gen set would not decrease when being operated under low temperature and high humidity regions the factors that may have an impact on normal operation of the Gen set under different site conditions must be taken into consideration also during model selection When the Gen set is going to be used under non standard environmental conditions users shall corr
60. ing which burns shall be paid attention to and prevented 2 2 Remove oil filter with tools clean surrounding of filter cover clean surface of seal ring or replace when necessary and remove the O ring that may closely attach on the rover Oil filter Washer Figure 9 2 Replacing oil filter 2 3 Operate filter correctly and fill clean lubricating oil in a new filter fully or the engine would be damaged because of short time oil shortage 2 4 Apply a thin layer of lubricating oil on surface of seal ring before installing 66 Diesel Alternator Set Operation Instructions new filter 2 5 Install filter to filter cover and then tighten it until washers contact with surface of filter cover closely Then retighten it 3 4 1 turn s more to seal it up 2 6 Check and clean drain plug and washers and then reinstall and retighten them 2 7 Fill new lubricating oil until its level 1s between the upper and lower scale mark of oil dipstick 2 8 Start the Gen set and keep it idle after engine oil is replaced to check if drain plug or filter leaks or not 2 9 Check level of engine oil again 5 minutes after stopping If oil level lowers to below lower scale mark refill lubricating oil until the level is between the upper and lower scale mark of oil dipstick 3 Replacing fuel filter 3 1 Turn off the engine to let it cool down in order to avoid damage from heat 3 2 Prepare a vessel to collect leaked fuel 3 3 Remove
61. isture and foreign objects 2 Preparations for equipment installation Before installation of the Gen set relevant equipment and tools e g crane forklift and wrench etc shall be prepared as per construction scheme II Requirements for installation of the Gen set 1 Size of equipment room 1 Size of equipment room of the Gen set shall meet space requirements for installation operation and maintenance of the Gen set 2 An opening for transporting of the Gen set shall be reserved in the equipment room in order to ensure that the Gen set can be moved to its installation position At least a 3500x2500mm opening for transportation shall be reserved for 20 120kW 35 Diesel Alternator Set Operation Instructions series Gen set 3 The equipment room shall provide enough space for maintenance of the Gen set and distance from edges of installed Gen set to wall surface shall not be less than 1 500mm 4 There are shall be enough space for arrangement of exhaust pipe at height direction of equipment room and height of equipment room for 20 120kW series Gen set shall not be less than 4 000mm Suggestion dimensions of the equipment room built for 20 30kW Gen set 40 75kW Gen set and 90 120kW Gen set shall be 4320mm L x3500mm W x4000mm H 4700mm L x3500mm W x4000mm H and 5150mm L x3500mm W x4000mm H respectively 2 Requirements for foundation Foundation of the Gen set must meet following requirements 1
62. l system bleeding During first commissioning of the Gen set be sure to check and confirm that there is no air in fuel at first If there is any air bleed it as per following methods 1 Bleed air in low pressure fuel pipe Loosen bolts and press oil delivery pump with hands to bleed air in fuel loop until the air 1s bled Then stop this operation and tighten bolts Figure 7 3 Air bleeding of low pressure fuel pipe 51 Diesel Alternator Set Operation Instructions 2 Bleed air in high pressure fuel pipe and fuel pump Loosen nuts and drive diesel engine to rotate with starter to bleed air in fuel pump and high pressure fuel pipe until fuel flows from high pressure fuel pipe continuously Then stop the operation and tighten nuts Figure 7 4 Air bleeding of high pressure fuel pipe 4 Check if all pipelines and joints in fuel supply system lubrication system cooling system and other systems of diesel engine are free from fuel leakage and water leakage 5 Connection of loaded cable Connect loaded power cable to air switch of the Gen set according to following requirements 1 Tighten with bolt assembly in the order of bolt spring washer flat washer connector and nut in order to ensure that connection wires contacts with each other well 2 Phase sequence of loaded power cable shall be kept consistent with phase sequence U V W and N of air switch 3 Be sure that these phases contact with each other w
63. lt to be removed shall be cleaned by adding detergents in low pressure hot water hose If some of the sediments which are difficult to be removed still cannot be solved by above methods it 1s necessary to remove the removed and immerse into a hot alkaline degreasing solution for about 20 minutes and then flush it with a hot water pipe 5 2 Internal cleaning of radiator 68 Diesel Alternator Set Operation Instructions The entire system would be blocked by rust scale because of leakage etc hard water in filled water or operation of the Gen set without anti rust agent Rust cleaning procedures of radiator are as follows 1 Drain water in the system remove and close interface connecting pipes and oil engine 2 Prepare anti acid solvent at the concentration of 4 and fresh water add anti acid solvent into water and pay attention to not reverse the order 3 After several minutes of mixing heat the solution to 49 C or under 4 Slowly pour the solution into radiator from a nozzle or bypass pipe then bubbles will appear After these bubbles disappear fill the radiator with hot solution fully 5 Keep the radiator vertical for several minutes and the drain the solution to its original container from branch pipe or drain plug at bottom 6 Check if there 1s any rust scale n water tank If any increase concentration of the solvent to 8 and repeat above procedures 7 After rust removal neutralize this acid solution
64. ly need to install as per local electric power rules and regulations 1 2 Do not open cover plate of alternator during operation of the Gen set or injuries or even death may be caused by electric shock 1 3 The air switch shall be turned to switching off position and the Gen set shall be stopped when operators perform maintenance on wiring harness of the equipment or injuries or even death may be caused by electric shock 1 4 Do not handle electrical failures while wearing wet clothes especially wet shoes or having wet skin 2 Fire hazard may cause injuries or even death of operators 2 1 Open flames and smoking must be prohibited in equipment room of the Gen set Battery and fuel of the Gen set are inflammable especially lead acid battery may generate explosive hydrogen when being charged and may cause personal injuries or even death because hydrogen may immediately cause an explosion if it 1 Diesel Gen set Operation Instructions contacts with electric arc or spark 2 2 When the Gen set is operating or hot do not add fuel into fuel tank It would be very dangerous if fuel contacts with hot body of diesel engine and exhaust pipe etc 3 Rotating parts may cause injuries or even death of operators 3 1 All rotating parts of Gen set shall be equipped with protective cover for example flywheel fan and charging alternator etc shall be equipped with protective cover In addition fastening condition of these rotating
65. m shall be able to freely flows in the alternator and bring away moisture Please introduce hot air into alternator from its air intake with two 1 3kW electric hair dryers Pay attention that winding shall be kept at least 300mm away from heat source in order to avoid damage of insulation caused by overheating Heat continuously and record insulation resistance value once every half hour The drying process will be completed when the resistance reaches to the valued specified in typical drying curve Start the Gen set again for commissioning after removing these heaters and reinstalling all cover plates If the Gen set does not operate immediately make sure that condensation removing heater installed on alternator is energized and operates normally Measuring of insulation resistance 1s still necessary before starting of operation next time 6 3 Short connection method 70 Diesel Alternator Set Operation Instructions Note this process must be carried out by a qualified engineer who is familiar with safe operation procedures of malfunctioned Gen set At first carry out all mechanical and electrical safe operations related to the Gen set and site in order to ensure operation safety of alternator Complete short connection of output end of Gen set with short circuit plates which can withstand rated current of alternator Disconnect connecting wires Fl and F2 connecting wire of AS440 and AS480 F and F connectin
66. n set Main checking contents are as follows 1 Check if speed of the Gen set is normal or not by viewing display screen of the module and it shall be approximately 700r min under idle operation 54 Diesel Alternator Set Operation Instructions 2 Check if oil pressure of the Gen set is normal or not The oil pressure shall not be lower than 0 15Mpa 3 Check if pipeline of fuel lubrication and cooling system leaks or not 4 Check if there is any abnormal noise or vibration and check connection and fastening condition of various parts 5 Check if exhausting 1s normal or not Belching of small amount of black smoke immediately after starting of the Gen set 1s normal 2 2 Operation under Rated speed If the Gen set is equipped with idling rated speed switch and operates normally after being started turn throttle control handle of diesel engine to RATED SPEED position and lock it after the Gen set has operated under idling state for 3 S5min If the Gen set 1s not equipped with idling rated speed switch the Gen set will automatically increase to rated speed in about 30 45s after being started After the Gen set reaches to rated speed check operation state of the Gen set again Main checking contents are as follows 1 Check speed and frequency of the Gen set normal speed and frequency of the Gen set 1s separately 1530 1560r min and 51 52Hz If speed and frequency of diesel engine is lower than 1 530r min or 51Hz
67. n the loose screw causing plunger to get out of control Bulb of adjusting arm of injection pump 3 plunger or rack is not in the groove of Contact with after sales service personnel control fork which keeps the plunger at for repair maximum oil level Oil supply control rack and moving parts of governor suffer from clamping Contact with after sales service personnel stagnation which disjoints oil flow control to repair or replace rack and pull rod of governor Lubricating oil in governor is too much MEME Inspect whether machine oil in oil pan is viscous or dirty which prevents the heavy Ae i too much and lubricating oil return line of hammer from being timely thrown off the governor is blocked Clean or replace if when speed rises and pull rod or rack necessary from controlling the governor Fuel injector spring is too weak or broken l MEA Contact with after sales service personnel which makes injection pressure too low to repair or replace leading to excess fuel in cylinder Pin roll of flyball of governor is broken and falls off which makes the flyball get detached Contact with after sales service personnel to repair or replace 5 Low lubricating oil pressure Serial ng Cause Elimination method number Problems of oil pressure gauge or Correct oil pressure gauge and sensor and m oil pressure sensor Fr them if necessary 2 Machine oil is insufficient Fill Fill machine oil
68. ning never remove any component of the Gen set when the Gen set is operating Warning when the Gen set is operating do not put your hands under protective cover of fan or other parts which move relatively 3 Warning of the Gen set Warning is not a serious alarm condition which would not have an impact on system operation of engine but only is used to remind operators of the conditions that do not meet with requirements When any warning occurs display panel will display corresponding trouble problems If these troubles are not locked the warning will be removed once these troubles are eliminated After troubles are eliminated press stop reset button o to release stop locking corresponding warning indicator light will turns off and Gen set 1s able to be started for commissioning 4 Stop of the Gen set 4 1 Normal stop 1 Remove loads at first proceed to switching off operation and let the Gen set operate without load for 3 5 minutes after being unloaded 61 Diesel Alternator Set Operation Instructions 2 Press stop button o and the Gen set will stop operating after 2 minutes the mechanically governing Gen set will operate 2 minutes under rated conditions while electronic governing Gen set will operate 2 minutes under idle mode 3 If you want to stop the Gen set directly press stop button o two times successively 4 Turn power switch to OFF position 5 Remove connecting cable from negative electrode
69. o terminal of AVR Restore the Gen set and reinstall all cover plates to carry out commissioning of the Gen set again If the Gen set does not operate immediately make sure that condensation removing heater installed on alternator is energized and operates normally Measuring of insulation resistance is still necessary before starting of operation next time Warning never carry out short connection of three phase winding when AVR and alternator is connected to a loop as winding will be damaged when current exceeds rated current of the alternator 6 4 Typical drying curve No matter the alternator is dried by what way record insulation resistance value once every half hour and tabulate these records into a graph as shown in Figure 9 4 Min insulation resistance 1 0MQ Insulation resistance Figure 9 4 Typical drying curve Figure 9 4 shows typical drying curve of a very humid alternator This curve shows that insulation resistance reduces and then rises to a stable value gradually after rising for a short period of time Insulation resistance under stable state at point A must be higher than 1 MQ If winding is only lightly affected with damp it may not be observed at dotted line part in the figure The drying process will at least last 1 hour when A point is reached 72 Diesel Alternator Set Operation Instructions Note insulation resistance will reduce significantly when temperature of winding rises Referenc
70. of battery and protect it with insulation tape Note never stop the Gen set operating with loads 4 2 Emergency stop In an emergency stop the Gen set will turn off throttle immediately after emergency stop button is pressed or fuel injection pump stop control handle is rapidly pushed to OFF position Emergency stop signal will be released only this button is pressed again Emergency stop must be activated immediately after any of the followings occur during operation of Gen set 1 Any abnormal sound or odor s heard or sensed during starting or operation of the Gen set 2 Oil pressure of the Gen set suddenly reduces to the limit or no oil pressure is detected 3 Speed of the Gen set is 115 higher than rated speed 4 Fire electric leakage or other natural disasters that may endanger safety of the Gen set and operators occurs Note do not activate emergency stop at random unless a special emergency 62 Diesel Alternator Set Operation Instructions occurs 63 Diesel Alternator Set Operation Instructions Chapter 9 Maintenance and Care of the Gen set I Maintenance and care schedule Interval Contents Clean oil stains and dust on Gen set Check level of diesel oil engine oil and coolant Daily Check if there 1s any air oil or water leakage Check if all electric circuits are getting loose or damaged or not Clean dust in dust exhausting bag of air filter Change engine oil and element of
71. of output voltage of Gen set is within 10 of rated voltage Voltage on the terminal 7 8 of AVR or terminal 3 4 of SE350 shall be 170 250V If output voltage of alternator is normal while that on terminal 7 8 or terminal 3 4 of SE350 is too low inspect the connection between auxiliary lead and main terminal The bulb between F1 and F2 F and F of SE350 shall be continuously on Rotate voltage regulation control potentiometer to the end and the light on AVR plate shall be off or dim If the light on AVR plate is on it indicates that AVR has been damaged and shall be replaced Note rotate voltage regulation control potentiometer counter clockwise to the end after the above test 1 If the voltage is balanced but too low main excitation winding or rotating diode may have problems Please execute the steps below to identify the problem Rectifier diode The diode on main rectifying component can be measured with multimeter Disconnect the flexible conductor connected to each diode at terminal and measure its forward and reverse resistance Sound diode shall have very high infinite reverse resistance and very low forward resistance The damaged diode takes on fullscale deflection or reading is infinite both in forward and reverse directions when measured at 10000Q When a sound diode is measured with electronic digital meter one reading will be low and the other reading will be high Replace the damaged
72. oil filter Clean fuel filter and element 50h Check belt and tension One time does not Clean air filter need to be Apply universal auto lithium base lubricating grease to water repeated pump bearing Clean dirt on electric brush and commutator of starter and lubricate bearing of alternator Change engine oil and element of oil filter Check water dropping condition at drain hole of water pump If it is severe replace the water seal Check if alternator and starter are installed firmly and check if electric brush or commutator is worn or not Check if wire joints of electrical apparatus are connected firmly 200h and replace it when any burn mark is found Check valve clearance and adjust it to specified value Clean parts of breather Check insulation resistance of alternator winding and dry it if it Check if element of air filter 1s in good condition or not is too low Clean air filter of Gen set Replace element and seal ring of fuel filter 500h Clean daily use fuel tank and various fuel passages Replace element of air filter 64 Diesel Alternator Set Operation Instructions Clean oil cooler or replace core of oil cooler if it is blocked Check and adjust angle of advance Check tightness of air valve Check if crankcase blows by and if belched some is blue replace piston ring when necessary Check wear of cylinder Jacket connecting rod bearing shell and main bearing shell etc and clean carbon deposit on cyl
73. onnel to adjust it Conduct regular maintenance as required 19 Diesel filter 1s blocked IE in instructions PESE Inspect and clean and replace if 20 Oil circuit is blocked necessary m ae Discharge air in low pressure and high Air in the oil circuit causes too great ae i 21 Mn pressure oil circuits with method in fluctuation of injection pressure instructions nn Replace oil and install oil water 22 There is water in oil separator 23 Matching parts of injector are damaged or Contact with after sales service suffer from poor atomization personnel to repair or replace Oil supply of fuel injection pump 1s Contact with after sales service insufficient or uneven personnel to repair or replace Maximum oil supply limit screw of fuel Adjust high speed limit screw injection pump 1s adjusted inappropriately m Contact with after sales service 26 Oil supply of oil pump is insufficient personnel to repair or replace 2 Abnormal noise or vibration of diesel engine in operation Serial Abe nei Cause Elimination method number The oil is injected untimely or oil supply of Adjust fuel supply advance cylinders is uneven causing clear and rhythmic angle or evenness of oil supply particularly intense in start up or at low speed Slight rhythmic knocking sound is made due to too 2 Adjust valve clearance big clearance of intake exhaust valve The diesel engine hasn t been warmed up before Remove the load swit
74. rber which intensifies vibration is disabled and replace it if so 3 Unsteady running of diesel engine Serial che ck Cause Elimination method number Individual cylinder is ignited intermittently which makes oil erupt too violently thereby Inspect fuel system knocking the cylinder Oil quantity and injection time of injection Inspect and adjust pumps are inconsistent Discharge water in the fuel There is water in fuel system system with fuel filter or replace the fuel Timing gear moves forward and backward Inspect fastening of gears Contact with after sales service Fault of governor personnel for repair 4 Overspeed of engine tue Discharge air in the fuel system 3 There is air in fuel system Np with method in instructions Serial TT Cause Elimination method number Damage to injection pump plunger or delivery valve seat deformation of plunger bushing due to too large tightening torque impurity in clearance of plunger pair too Contact with after sales service personnel thin gasket on positioning bolt of plunger l EN to recalibrate or replace the injection pump bushing or jamming of plunger bushing due to too long bolts etc during repair or assembly can make injection pump plunger inflexible or stuck at the position of maximum oil supply Fixing screw of gear ring for adjusting oil caf Contact with after sales service personnel flow of injection pump plunger gets loose to faste
75. rect EM personnel to maintain or replace Fuel injector fails and atomization of diesel Contact with after sale service oil is poor personnel to maintain or replace Blue some burning of engine oil l a l Drain surplus engine oil until Too much engine oil is filled to oil pan and l mM l level of engine oil in oil pan is enters into combustion chamber when l between H and L oil level of diesel engine operates mE dipstick Clearance between piston and cylinder Jacket increases and engine oil enters into Increase loads properly or select combustion chamber after long period of a Gen set with proper power low load 30 or under operation Piston ring is stuck or worn excessively Replace piston ring 71 u Amount of fuel supplied to fuel injection Contact with after sale service Diesel Alternator Set Operation Instructions E and less in elasticity or engine oil enters into combustion chamber Unburned fuel mixture 1s exhausted with waste gas during initial starting of diesel Normal phenomenon engine especially in water or when ambient temperature 1s low personnel to maintain or replace into cylinder Replace fuel and add oil water separator There is water and air in fuel Bleed air in fuel system according to the method specified Cylinder jacket cracks or cylinder head Contact with after sale service gasket is damaged or cooling water enters in Chapter 7 78 Diesel Alternator Set Opera
76. ring of key switch Fault of flameout controller Repair flameout controller Inspect whether oil return pipe is blocked 4 Blocking of oil return pipe warped or sunken and replace it if necessary l 2 3 Chapter 11 Service Commitment Dear users Welcome to use Weichai products Thank you for your favor of Weichai products In order for correct use and maintenance of the Gen set please carefully read instructions for use and maintenance and operate n strict accordance with relevant provisions If the diesel engine breaks down please contact with Weichai repair service center or customer service center as soon as possible We will provide timely and effective repair service for you Weichai Generating Equipment Co Ltd Address No 197 A East Fushou Street High tech Industrial Development Zone Weifang Shandong Post code 261001 Website http www weichaihm com Tel 400 0536 988 I Service Concept Customer satisfaction is our purpose II Service Commitment The repair service center of our company guarantees to arrive at the site within 3h in the city 24h in general areas and 48h in remote areas in the service area upon receiving user information and confirming that service 1s needed except for force majeure III Principle and Provision of Quality Warranty Three Guarantees On the premise that users observe operating instructions for Gen set our company will be responsible for repairing or repla
77. rn clockwise to Prevent voltage swing increase damping effect Turn clockwise to Set UFRO knee point decrease knee point frequency Common ground Excitati Detect on ire Power input output M sj t dr inca regulation connection Connect 8 and Z2 when there is no auxiliary winding KRS440 Droop adjustment a adjustment Transient response selection u I Under frequency E i Indicator li subiti roll off Y Y 2 Sr colle oo co Frequency selection qD RA 60 C 50 cs J LP L 50Hz 60Hz Law i p Figure 3 8 KRS440 Wiring diagram 1 Stability adjustment shall be selected as per Table 3 5 16 Diesel Gen set Operation Instructions Table 3 5 Stability selection list 2 See Table 3 6 for roles and adjustment methods of AVR adjustment potentiometer Table 3 6 Function list of KRS440 adjustment potentiometer Control button Direction of adjustment Adjust output voltage of Turn clockwise to increase Voltage adjustment alternator output voltage l Turn clockwise to increase Under Frequency Roll Off Prevent voltage swing stability Droop is Gen set to 5 Droop applicable for Turn clockwise to increase when OPF is fully parallel connection droop loaded T Turn clockwise to increase stability Prevent voltage swing damping effect Turn clockwise to increase Optimize sensitivity of PF control adjustment control on
78. t is started Note if starting is not successful try again approximately 20s later If starting does not realized continuously for 3 times top starting and try again after battery voltage or fuel pipe etc related trouble factors are eliminated 2 Operation of the Gen set 2 1 Normal start After the Gen set is started successfully operate it under rated conditions to check operating state of the Gen set Main checking contents are as follows 1 Check speed and frequency of the Gen set normal speed and frequency of the Gen set is separately 1530 1560r min and 51 52Hz 2 Check three phase output voltage of the Gen set with voltmeter and 59 Diesel Alternator Set Operation Instructions three phase voltage change over switch The value shall be 400V 3 Check if water temperature and oil pressure of the Gen set 1s normal or not Water temperature shall be lower than 95 C and oil pressure shall be higher than 0 15Mpa 4 Check if lines of fuel lubrication and cooling system leak or not 5 Check f belched smoke s normal Belched smoke of the Gen set shall be colorless It is abnormal if large amount of black smoke blue smoke or white smoke is belched from this diesel engine 2 1 Operation with load If the Gen set operate normally switch on breaker after the Gen set warms up at Rated speed to let the Gen set operate under load At this time inspect operating condition of the Gen set The main inspection items ar
79. ter in diesel oil MEERE I Air intake system malfunction starter operates but diesel engine does not start Air intake system leaks air Inspect and maintain __ Intake manifold is blocked Clean air filter see Chapter 9 for Aur filter malfunctions specific method Intake or exhaust valve leaks air Adjust valve clearance m Air cylinder leaks air Replace piston ring 2 Diesel engine belches smoke Troubleshooting Black smoke diesel oil is not burnt fully 76 Diesel Alternator Set Operation Instructions l Clean air filter and replace when Air filter malfunctions necessary Clean intake manifold and Intake manifold 1s blocked replace when necessary Discover fault point and have it Air intake system leaks air mE maintained or replaced u Contact with after sale service Valve clearance is incorrect mE personnel to maintain Insufficient cylinder compression pressure l Replace piston ring caused by wear of piston ring Thin air caused by extremely high Consult with sales personnel to temperature or altitude correct power of the Gen set Insufficient fuel injection pressure caused Contact with after sale service by malfunction of fuel injection pump personnel to maintain or replace pump is too large personnel to adjust Speed governor of fuel injection pump Contact with after sale service malfunctions personnel to maintain or replace a Contact with after sale service Fuel supply timing 1s incor
80. tion Generally anti freeze is used as coolant of the Gen set Anti freeze is one kind of coolant containing special additives Anti freeze refilled in engine has following functions 1 Ensure that engine operates in a normal temperature range 2 Prevent corrosion of parts in cooling system 3 Prevent water scale and avoid efficiency reduction of radiator 4 Effectively prevent boiling of water tank in summer 5 When stopping the Gen set while ambient temperature n winter is low be sure to prevent radiator and cylinder block or head of engine from being damaged by expansion of frozen coolant The anti freeze to be selected will be different when ambient temperature s different For details of coolant grade please see Table 7 1 Table 7 1 Domestic long life anti freeze Grade Item 47 Diesel Alternator Set Operation Instructions Content of ethylene glycol Specifi it an 1 05 1 074 1 082 15 6 C Boiling point C 104 51 108 51 1101 Freezing point C Applicable minimum l 10 26 35 air temperature C Note do not only use water as the coolant Note anti freeze shall be stored at a dry and cool place and kept away from bright sunlight 1 2 Method for refilling of coolant Slowly fill coolant into cooling system from filler on radiator until level of coolant in radiator is 5cm away from filler in order to bleed residual air in cooling system of engine 2 Refilling of oil 2 1 Oil selection
81. tion Instructions 3 Engine hunting Troubleshooting Fuel supply control rod of fuel injection pump moves inflexibly or normal Contact with after sale service l functioning of regulator is damaged then personnel to recalibrate or amount of pumped fuel fluctuates and replace operating stability of engine is influenced Contact between parts of speed regulator is too tight and resistance of motion is too Contact with after sale service large fuel supply control rod moves personnel to maintain inflexibly Check if amount of engine oil in Too much engine oil is filled into speed l l oil pan is too march and regulator extending and retracting of mE mE lubricating oil return pipe of centrifugal weight 1s blocked and sensitivity l speed regulator is blocked or is reduced because of damping action of oil not and have it cleaned and fluid replaced when necessary Various connecting points of speed regulator are worn excessively contact 1s loose and clearance increases When speed of engine changes all clearances shall be eliminated in turn under centrifugal thrust of flyweight and then fuel supply adjusting rack or Contact with after sale service personnel to recalibrate or replace shifting fork 1s driven to increase or decrease amount of fuel being supplied in order to delay functioning of speed regulator Injection timing is incorrect atomization 1s poor and fuel injection pressure at nozzle s
82. ure and function of AVR are described below respectively 3 1 AS440 10 Diesel Gen set Operation Instructions en F2F1 7 sllsz2l BEER AS440 Stability selection Tumper Frequency selection Jumper N oou n 50H D i LED indicator light ri l 2 c ni C Al wer LE on ee Figure 3 4 AS440 Structure diagram 1 Generally terminal 8 and Z2 are short connected However if the alternator is equipped with auxiliary winding they shall be disconnected and connected to auxiliary winding 2 As shown in Figure 3 5 terminal 7 and 8 are connected to main stator armature of alternator and terminal Fl and F2 are connected to exciter stator magnetic field 11 Diesel Gen set Operation Instructions Excitation rotor ff YY Y YN J H Main rotor magnetic field CN ov Y Y NN Main stator armature Rotary rectifier XY wv xwv Y Y x INN NN Excitation stator Manual voltage potentiometer E Zr o jew hoa on uo uw 7 N 2 V d Pos 9 Low voltage mode _ gt o c m AS44 Note 11OAVR input terminal Regulating current mr St Manual voltage potentiometer shall be equipped with twin core transformer r kes2 R2 NN P uin shielded wire connecting to alternator casing or being PLAT S2 pi h aens aiea et al grounded directly 4 S Stator winding l Output terminal Figure 3 5 AS440 Wiring diagram
83. xhaust port of diesel engine to outside of the equipment room The exhaust system consists of silencer bellow flange elbow and gaskets associated with the engine as well as exhaust pipe connecting it to outside of equipment room Design of smoke exhaust system of the Gen set shall meet following requirements 6 1 Allowable maximum exhaust back pressure of diesel engine shall not exceeded or performance of diesel engine would be influenced power of diesel engine would be reduced and fuel consumption exhaust temperature and emission shall be increased In order to reduce exhaust back pressure following measures shall be taken 39 Diesel Alternator Set Operation Instructions 1 Number of elbow shall be reduced as much as possible and the number of 90 elbows shall not be more than three 2 Internal bending radius of 90 elbow shall be no less than 3 times the diameter 3 Total length of exhaust pipe shall be shortened as much as possible 6 2 The exhaust system shall be equipped with expansion joint to adapt to unreasonable installation of exhaust pipe or rigid deformation caused by thermal expansion during operation of the Gen set and absorbing vibration of exhaust system parts 6 3 Fixation of exhaust pipe exhaust pipe shall be supported and fixed with the help of buildings or steel structural If exhaust system is fixed by suspension on ceiling exhaust pipe shall be at least 2 5m high above the ground in order to

Operation & Maintains Manual of Weichai Group Diesel Gen-set

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Operation &amp; Maintains Manual of Weichai Group Diesel Gen-set

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Operation & Maintains Manual of Weichai Group Diesel Gen-set