DIESEL GENERATOR GROUPOPERATING & MAINTENANCE MANUAL DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL DEAR THE USER OF EMSA GENERATOR; First of all thank you for choosing Emsa generator. This operating and maintenance manual is prepared and developed to introduce you Emsa generator system. This manual gives general information about installation, operation and maintenance of the generator. Moreover general information, tables and schemas related the generator you have purchased are provided here. Never operate, maintain and repair your generator unless you take safety measures. 2 DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL TABLE OF CONTENTS 1. INTRODUCTION .........................................................................1 2. SAFETY ....................................................................................2 2.1 General .........................................................................2 2.2 Installation, carrying and towing ..........................................2 2.3 Fire and explosion ............................................................2 2.4 Mechanics .....................................................................3 2.5 Chemical ........................................................................3 2.6 Noise .............................................................................3 2.7 Electrical ........................................................................4 2.8 First aid in case of electric shock .........................................4 3. GENERAL DESCRIPTION .............................................................6 3.1 Definition and description of the generator ............................6 3.2 Diesel Motor ...................................................................6 3.3 Motor electrical system ......................................................6 3.4 Cooling system.................................................................6 3.5 Alternator ........................................................................6 3.6 Fuel tank and frame...........................................................6 3.7 Vibration isolators ............................................................6 3.8 Silencer and exhaust system ...............................................6 3.9 Control system..................................................................6 4. INSTALLATION, REMOVING AND STORAGE ................................8 4.1 General .........................................................................8 4.2 Cabin............................................................................8 4.3 Moving of the generator ....................................................8 4.4 Selection of generator place ..............................................8 4.5 Installation of vibration isolation ..........................................9 4.6 Combustion ventilation .......................................................9 4.7 Cooling and ventilation......................................................9 4.8 Exhaust ........................................................................10 4.8.1 Dimensions of generator room ..................................11 4.9 Fuel system ..................................................................13 4.9.1 Daily fuel tank ......................................................13 4.9.2 Main fuel tank ......................................................14 4.9.3 Fuel road ............................................................14 4.10 The oil used at the generator and antifreeze ......................16 4.10.1 Viscosity and temperature diagram..........................16 4.11 Batteries .....................................................................17 4.11. 1 Well-kept type batteries .......................................17 4.11.1. Filling battery with the first acidic water ..................17 4.11. 1.2 Battery care ............................................17 4.11. 1.3 Testing of battery ......................................17 4.11. 1.4 Hydrometer Test .......................................18 4.11.2 Neglectred type batteries ......................................18 4.12 Electrical connections ....................................................18 4.12.1 Wiring ..............................................................18 4.12.2 Protection ...........................................................18 4.12.3 Loading ............................................................18 4.12.4 Power factor ......................................................19 4.12.5 Grounding/grounding conditions ..........................19 4.12.6 Parallel operation.................................................19 4.12.7 Isolation test .......................................................19 4.13 Sound silencer .............................................................21 3 DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 9.1.3 AMF 4.0 Automatic Transfer Device ..........................24 10. LOCATION AND REPLACEMENT OF POWER BOARD ................26 11. FAILURES OF ALTERNATOR AND RECOVERY ............................27 12.FAILURES OF DIESEL MOTOR AND RECOVERY...........................28 13.PERIODIC MAINTENANCE INSTRUCTION ..................................30 4.13.1 Exhaust silencers .................................................21 4.13.2 cabins ..............................................................21 4.13.3 other sound silencers ............................................21 4.14 Towing of the generator with trailer ..................................21 4.14.1 Preparation for towing ..........................................21 4.14.2 Towing .............................................................21 4.14.3 Parking .............................................................21 4.15 Storage.......................................................................21 4.15.1 Storage of motor .................................................21 4.15.2 Storage of alternator............................................21 4.15.3 Storage of battery ...............................................21 4.16 Motor Block water heater ...............................................21 5. GENERATOR CARE ...................................................................22 6. CONTROLS AND PROCESSES TO BE CARRIED OUT BEFORE THE STARTING OF THE GENERATOR.........................................22 7. GENERATOR CONTROL SYSTEMS ..............................................22 8. OPERATION OF THE GENERATOR.............................................23 8.1 Operation instruction of automatic generator .......................23 8.1.1 Operation with DKG 307 Control Panel ...................23 8.1.2 Operation with EOAM 210FD-FL Control panel...........23 8.1.3 Operation with AMF 4.0 Control Panel .....................23 8.2 Operation instruction of manuel generator ..........................23 8.3 Points to be noted while starting up ...................................23 9. INTRODUCTION AND OPERATION INSTRUCTION OF AUTOMATIC TRANSFER DEVICE ........................................................................24 9.1 DKG 307 Automatic Transfer Device.............................24 9.1.1Digital indications ...................................................24 9.1.2 EOAM 210 FD-FL Automatic Transfer Device: .............24 4 DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 1. INTRODUCTION Emsa Generator is designed to be applied to the circuit immediately wherever it is taken as long as cooling water and its antifreeze, fuel, lubricating oil and charged battery are provided. EMSA manufactures efficient, reliable and high-quality generators by means of experience of long years. This operation and maintenance manual is prepared to help the user about using and performing maintenance of the generator easily. In the event of following recommendations and instructions in this manual, maximum performance and effect can be obtained. In order to ensure regular operation of generator in dirty and dusty environment, it should be noted to maintain more frequently. Settings and repairs should always be performed by authorized and qualified personnel. Every generator, frame has the model and series numbers shown on the label. Moreover, manufacture date, current, voltage, power term of kVa, frequency, power factor and its weight are indicated on this label. This information on the label is necessary for ordering spare parts, processing o guarantee or providing service. Gen - Set Type Gen - Set Serial No Engine Type Engene Serial No Alternator Type Alternator Serial No Power (kVA) Voltage (V) Frequency (Hz.) Current (A) Speed (rpm) Cos Φ Phase (kg) Production Year Nominal Voltage Weight (kg) Max. Height Max Temp.( C) Performance class EMSA Elektromotor Alternatör San. Tic. A.fi. Meclis Mah. Teraziler Cad. No:37 Sarıgazi/İstanbul Tel: +90 216 420 00 03 (pbx) Fax: +90 216 364 45 00 e-mail: [email protected] www.emsa-jenerator.com.tr Figure 1.1 EMSA Generator Label 5 CARRYING AND TOWING • Section 4 covers installation. • Generator must be installed and operated by authorised service personnel in accordance with the standards. • In the event of not following procedure. WARNINGS WARNINGS • Perform the electrical connections as per the relevant standards. operate and maintain the generator. standards and other requirements. Ensuring the necessary safety before any technical operations or processes is dependent on the one who performs that operation or process. Exhaust gases of all generators indoors must be disposed with proper. 2.1. • Please make sure that fuel storage systems for generators are mounted in accordance with relevant codes. Read this section before carrying. If the safety precautions indicated are applied. Please ensure disposal of exhaust gases out of • If there is an unsafe condition in the generator. leak proof. Please note the safety precaution stated below. black pipes as per the relevant standards. In addition to this. safety responsibility belongs to the ones who install. instruction and safety precautions in this book.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 2. • Before maintaining and cleaning of generator. The generator can only be operated by authorized and qualified personnel. Grounding and grounding failures are included in these standards.2 INSTALLATION. the possibility of accident is very low. GENERAL The generator is designed to be safe completely provided to be operated correctly. installing or towing the generator with trailer. accident and injuring are likely to increase. • Motor exhaust gases are dangerous for personnel. • Do not operate the generator in the event of known unsafe condition. Hot exhaust silencer and exhaust pipes should be protected against being contact with flammable objects and touching of personnel. • Please read and understand all warnings in this manual before operating or maintaining the generator. 2. disconnect negative 6 . put danger warning and prevent operation of generator by disconnecting of negative (-) pole of battery until correction of this negative condition.SAFETY (-) pole of battery. lifting and storage of generator. Necessary hardware and speed limits expresses explicitly in the regulations are included. • There must be an emergency exit door for personnel's easy existing in the event of any fires. clean the spilled area immediately. you should note all traffic rules. Personnel must know how to use them. • Keep grounded conductive objects away from areas being exposed to electricity such as terminals.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL danger.1). While towing the generator with trailer. Sparkle or arc may inflame the fuel. oil. Class BC and ABC fire extinguishers must be kept handy. • Fuel and smoke being parts of generator can flame and explode. do not install and operate the generator in an environment characterized as dangerous. • Keep clean the Generator. In order to lift up the generator use the lifting points on the frame. (Figure 4. 7 . In the event of spilling of fuel. When the Generator is lifted all personnel should be kept away the generator. generator room and the floor. Taking proper precautions during the storage of these materials can be reduced fire and explosion risks. do not fill the fuel tank. • Make sure that lifting devices and support structures are durable and have the capacity of bearing the generator. Do not allow personnel to stand on the towing bar or between mobile generator and wrecker. • Do not keep flammable liquids near the motor. battery electrolyte or cooling water around. spark around fuel. WARNINGS • Do not lift up the generator . • Do not allow events to cause the combustion such as smoking.3 FIRE AND EXPLOSION • Do not operate the generator if there is fuel leakage in the fuel system. 2. • Ventilate the generator room properly. standards and other regulations. disconnect feeding of battery charger. • Unless designed distinctively. flame. • Before performing connection or disconnection of battery connection. • Do not allow personnel to travel on the mobile generator. in order to avoid arc event. alternator and motor via lifting rings. • While motor is working. overhang clothes parts should be kept away from moving parts of generator. WARNINGS WARNINGS • Do not operate the generator in the event of safety housings' are not in place. • Keep closed and locked the Generator room. • Avoid contacting of hot fuel. • Use protective clothes and materials while working at generator site. face mask and safety goggles. long hair. seek medical treatment immediately. loose the hole slowly for reducing the high steam pressure. clean the area spilled plenty of pressurized water immediately. Caution: Some moving parts are not seen visibly. • Hand. hot surfaces and sharp corners. Yet. arm. Do not attempt to reach near or under of safety housing for maintaining or another reason while the generator is working. If swallowed accidentally. While preparing the battery. Generator is designed with its housings in order to be protected against moving parts. cooling water and battery electrolyte used in the Generator are industrial type.5 CHEMICAL Oils. In case of spilling of battery electrolyte on the skin or clothes. they may harm the personnel. • Do not contact fuel. In the event of contacting with skin. hot exhaust gas smoke. 2. precaution should be taken to protect personnel and devices against other mechanic hazards while working in the generator room. If not used properly.4 MECHANIC cooling water has cooled. oil. hot cooling water.6 NOISE • Do not open the cell filler hole of radiator until Loudness level of generators not being equipped with sound isolation 8 .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 2. • Do not wear clothes contaminated by fuel or oil. Before opening the radiator hole completely. wash contact area with soup and water. 2. jewellery. wear acid-resistant overall. cooling water and battery electrolyte with skin and swallow. connection cables and electrical parts on the Generator with any parts of your body or any objects not being isolated. WARNINGS • Wear headphone while working in the generator site. using and maintaining of these devices properly. • Before connecting or disconnecting load to generator. • Do not contact with conductor. Replace the terminals having abraded. Efficiently and secure working of electrical devices is provided with installing. • Use Class BC or ABC fire extinguisher in case of electric fires. corroded and faded. stop operation of the Generator and disconnect the negative (-) terminal of battery. • Isolate all connections and idle wires. • Do not attempt performing load connecting or disconnecting while standing on wet or watery ground. do not start up the generator. • Before starting up the Generator. fix the cover of alternator its place. Keep clean the terminals and perform connections tightly.7 ELECTRICAL • After performing load connection or disconnecting load. cracked and broken. Unless the cover is not fixed securely.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL cabin is more than 105 dBA.. WARNINGS • Keep all electrical equipment clean and dry. 9 . • Connect the generator to loads and electric systems conforming to its electrical characteristics and power. Long term exposure to loudness level more than 85 dBA is dangerous for hearing. Replace the electrical system where isolation has abraded. 2. (including mobile generators) make sure that grounding of the generator has been performed. • Attaching of generator with the load should be performed by authorised and qualified service personnel in accordance with relevant electric codes and standards. IF HE CAN NOT BREATHE BUT THERE IS PULSE Close the nose of survivor tightly. come back in a short time with breathing out for 10 times again and continue the action of breathing out. After every breathing out. chewinggum. unplug it or move away the electric cable from the one being exposed to the electricity. control the pulse.8 FIRST AID IN CASE OF ELECTRICAL SHOCK CAUTION via seeing. Then permit thoracic cage to go down completely through stopping blowing. position the survivor as the way described below. Breath out the survivor for 2 times and start cardiac massage as described below. hearing and feeling. Position your palm above 2 finger from the junction of thoracic cage. stand on dry. If not. • If the survivor breaths. Give breath for 10 times average per minute to the survivor. If the survivor is left unattended so as to call for help. • Do not touch with bare hand to the person being exposed to the electricity before switching off the electric source.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 2. Position the survivor in recovery position when he starts breathing. 10 . • If the person being exposed to electricity has lost his consciousness. Remove the objects getting into mouth or throat of the survivor such as false teeth. perform the treatment stated below to bring round: IF HE CAN NOT BREATH AND THERE IS NO PULSE Seek medical assistance or call the nearest health institution. cigarette. • If possible deactivate the electric source. BLOOD CIRCULATION Control the survivor's pulse from his neck. Unite your lips with survivor's lips via taking deep breath. move away the one being exposed to the electricity via using preferably dry wood. DECONGESTING THE RESPIRATORY TRACT Hang the head of survivor backward and lift up his chin. non-conducting material. • If they are not possible. blow from the mouth observing the rising of thoracic cage. BREATHING Control whether the survivor is breathing or not Position your other hand locking your fingers. repeat the actions described above. 3. Control his breathing and pulse regularly.2 DIESEL MOTOR Diesel motor (1) driving the generator is chosen since it is manufactured especially for generator and secure. So as to ensure the respiratory tract's being open keep his head leaning in such a way that his chin will look towards. Figure 3. this system consists of electrical starter motor. industrial heavy duty type and all accessories for enduring safe energy are provided on it. If either of them stops.C.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Holding straight your arms press 4-5 cm down 15 times per minute. Model and series number only define that generator and they are necessary in the event of processing of guarantee. battery and battery charge 11 . process and 15 times cardiac message until medical aid comes. weight and manufacture date. Control his pulse after every 10 breathing out. The motor is four-cycle. More detailed information is provided next sections of this manual. RECOVERY POSITION Lay the survivor sideward. condition of the survivor.3 MOTOR ELECTRIC SYSTEM 3. demanding service and spare parts. Exchangeable dry type air filter. mechanic or electronic engine speed control governor are some of these accessories. But every generator shows difference as per the configuration and sizes of main components. GENERAL DEFINITION 3.1 shows the main parts of a typical generator.1) This label contains information describing the generator and working characteristics of generator. In every generator a label pertaining to that generator is stuck on the frame. Emsa Generator is designed as a whole to ensure high quality and security. alternator voltage and frequency. out power as kVA. series number. As soon as he begins to breath convert him recovery position. continue breathing out via controlling his pulse. This section describes parts of generator group in short. 3.1 DESCRIPTION AND DEFINITION OF GENERATOR Motor electric system is negative grounded 24 ›r 12 v D. This information is model number. Ensure the survivor not to tumble forward and backwards. WARNING • Do not give liquids such as water until the survivor has gained his consciousness again. (Figure 1. special insulators can be used between frame and ground.8 SILENCER AND EXHAUST SYSTEM Exhaust silencer is provided with the generator and/or separately for mounting (2). too. Terminal box made of steel plate (5) is mounted on the alternator.4 COOLING SYSTEM Motor cooling system is air cooled or water cooled. The silencer and exhaust system reduces the noise spreading from motor and orients the exhaust gas for a safe output. 3. If desired. and brushless. These insulators are placed between motor and alternator stays and frame.cooled system consists of radiator (3). There is built-in fan in the alternator to cool the winding of alternator. Detailed information on these systems are provided in Section 7. other type batteries can be provided.2 for capacities of fuel tank).5 ALTERNATOR 3.7 VIBRATION INSULATOR Vibration insulators (8) are used for preventing the generator's conveying vibration to the ground it has been installed via reducing the vibration of motor.6 FUEL TANK AND FRAME Motor and alternator are mounted on a steel frame (6). self-regulation. recirculation pump and thermostat.9 CONTROL SYSTEM Output voltage and power of generator is produced by the alternator (4) which has protected cage IP 21-23 protection Standard (protected against particular and dripping). 3.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL alternator.For 12 V electric system one and for 24 V electric system two uncared type starter battery are provided. 3. is self-warned. control the operation and output of the generator. An air-cooled system includes a high fan to cool the motor which gives cool air inside of the motor. 12 . fan. 3. There is fuel tank inside of the frame (7) (see Table 4. Manual or automatic control system and panel (9) are mounted on the generator so as to protect the generator against possible failures. Water. If requested. 3. Batteries are explained in details in Section 4. Terminal Box 6. Vibration Insulators 13 9. Frame 7. Control Panel . 3. 2. 4. Fuel Tank (inside the frame) 8.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 5 2 3 1 8 7 4 6 9 Figure 3. Diesel Motor Exhaust Radiator Alternator 5.1 Typical generator group 1. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. This section includes necessary and important factors for safe and efficient installation of generator.1 Lifting of generator with crane 14 .1 GENERAL When the Generator is put in a cabin. After being familiar with dimensions of the Generator. INSTALLATION. Cabin protects the generator against using of unauthorised persons and exterior factors.2 CABIN 4. the plan for installation of generator can be arranged. moving and installation will be very easier. Figure 4. LIFTING AND STORAGE 4. • When the generator is lifted up for the purpose of carrying. • While the generator with cabin or without cabin is being lifted. keep personnel away from the Generator. excessive temperature. Basement floor plan of a typical generator group is shown on Figure 4. -Ground of Generator room should be flat and stable. steam and motor exhaust smoke that abrade or provides conductivity . Moreover. Wrong lifting of generator may cause serious damages of parts. Generator can be lifted via using forklift. use lifting ring bolt holes on the frame. perishing cold. oil smoke. 4. If the generator is installed above the ground. If the generator should be placed outside of the building.4 SELECTION OF GENERATOR PLACE Following factors should be taken into consideration while selecting the place where the generator will be put: -There should be enough ventilation. thread. service and maintenance of the generator. the building structure must have the capacity of 4. motor and coupling of the alternator. -There should be at least 1 meter space around the generator and 2 meter space over it so as to perform cooling. Generator foundation: For generator foundation.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. • Take necessary precautions in order not to damage parts that are contacted with steel rope or chains to be used for lifting up the generator.4. Reinforced concrete reduces the vibration enabling hard and durable ground. WARNINGS • Do not lift up generator via using motor or alternator lifting rings. Place forklift blades (brackets) under the generator frame carefully. the generator should be put in a cabin or a room. -There should be proper way for carrying the generator to the room. 15 . certainly put wood between frame and forklift. direct sun light. The ground that foundation subsides should have the structure that can bear wet weight of foundation and the generator. flood water. In order to avoid damages which are likely to occur during carrying with forklift. -It should be protected against rain. snow. using of cabin during the operation of generator indoors or outdoors is beneficial. -Access of unauthorised persons to generator site should be restricted.3 CARRYING OF GENERATOR -It should be protected against harmful materials carried from air such as dust. there should be reinforced concrete ground being 15-20 cm high and having at least dimensions of generator. • Use proper equipment for weight of Generator. -It should be protected against of tree or beam that can fall and crash over.5 INSTALLATION OF VIBRATION ISOLATION Vibration insulators should be used between motor-alternator stays and frame after generator. Note that both frame brackets will be on the forklift blades. smoke. Generator frame is designed to make easy the carrying of generator. (Figure 4. Figure 4. fan reduces the efficiency of cooling via expanding hot air in the generator room. But sometimes air around the generator may not be suitable because of dust. Figure 4. For this reason. enough ventilation should be provided so as to keep cool motor and alternator. air must enter the generator room by alternator.3 poor ventilation assembly Air inlet and output Windows should be large enough for being easy of air inlet to the room and output from the room. to circulate the air ejected outside. 4. Under these circumstances. Increasing of temperature affects negatively working of the generator. ground of generator must be elevated. exist from the room by means of flexible bellows canvas made of tent canvas passing over the motor and through radiator.5 times than radiator area on the basis of a rough estimate.3).6 COMBUSTION VENTILATION Motor combustion air must be clean and cold as much as possible.2 orienting of air ejecting from radiator with deflection channels A sharp corner between radiator hot air ejecting channel or funnel should be avoided. Air inlet and output Windows should be larger 1.7 COOLING AND VENTILATION Motor and alternator release heat and cause increasing of ambient temperature.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL enduring the generator. Combustion air is drawn from the environment where the generator is via air fitler mounted on the motor. fuel tank and other accessories. If a canvas is not used for ejecting hot air out of the room. This channel ensures clean air for the air filter on the motor from outside or another room. dirt and temperature conditions. Air flow should be as seen on Figure 4. (Figure 4.2).4. 4. directing arrangement should be done. So abrasiveness of frame will have been reduced. In order not to affect generator by bad weather 16 . If Generator room is sometimes wet. air inlet channel can be provided. louver can be opened immediately after motor starts to operate and closed immediately after the motor stops. a flexible connection between exhaust manifold and exhaust pipe system. Figure 4. • In order to prevent conveying of motor vibration to exhaust pipe system and building. WARNINGS • It is dangerous to inhale motor exhaust gas. These louver may be fixed. Every necessary elbow must have arc at least 1. and due to the expansion resulting from heating. but it is preferred that they should be moving for cold climates. exhaust pipes must be short and flat as much as possible. Louvers can be closed while generator is not operated. Gases of all generator in the closed area must be ejected with leak proof pipes in accordance with standards.5 times radius more than inner diameter of pipe. So as to reduce loudness level of motor a proper exhaust silencer should be fixed to the exhaust pipe. By this means.4 Basement floor plan of typical Generator group 17 . So hot air facilitiating first starting up and providing to the load stays in the room. It will be good to use 1 inch larger pipe diameter at every 6 meters or 3 elbows for reducing exhaust back pressure. • Weight of exhaust pipe should be supported by surrounding structure for not being weight for motor manifold. • Keep away hot exhaust silencer and exhaust pipe from flammable materials and ensure them to be protected for the safety of personnel.8 EXHAUST The aim of motor exhaust system is to eject exhaust fumes outside the room in order not to cause danger and discomfort and reduce the noise.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. In order to reduce back pressure. Weight of exhaust conditions. inlet and output Windows must be louvered Windows. Excessive back pressure causes motor to be damaged. • It is noted when designing the exhaust system that back pressure shall not exceed the pressure values instructed by the motor manufacture. Louvers can be moved automatically if they are moving in a generator room having automatic control system. Figure 4.Table 4. Note: Please consult your dealer about groups with Remote radiators. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 18 . sizes of air inlet and output Windows and measures of exhaust diameter.1 Emsa open type diesel generator sizes.5 please see the letters provided at generator room. room sizes. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. For this reason. Exhaust outputs of generators can not be connect using only one exhaust pipe. Generator fuel system should continuously clean fuel for the motor. (up to 880 kVA). sparkle or smoking around the fuel. Main fuel tank should be placed somewhere outside the room so as to perform filling and maintenance easily. Steel frame of generator is manufactured as tank-frame to store daily fuel tank.5 Generator room 19 . Tensile element can be used for this.1 DIMENSIONS OF GENERATOR ROOM 4.2). fuel hoses and main fuel tank.8. 4.1 Daily fuel tank: Daily fuel tank keeps the daily fuel that generator needs ready to use. daily fuel tank should be at generator room. WARNINGS • Fuel storage systems of Generators must conform to standards.9 FUEL SYSTEM system should be given to the building. 4. The fuel system consists of daily fuel tank. • Exhaust material should be of metal pipe.9. • Every generator must have its own exhaust system. Note: For larger force please consult your authorised sales representative (Table 4. • Do not allow events being likely to cause fires such as flame. Silencer and exhaust pipes should be placed away from flammable materials. • Generator room should be isolated for loudness level of exhaust parts and heat released.9. But since at cold Figure 4. • Opposite weights flap type rain covers can be used for preventing rain inlet to exposed exhaust outputs with different applications.2 Main fuel tank: The main fuel tank can be installed in addition to daily fuel tank for providing operation of Generator longer. Table 4. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 20 .2 Fuel tank capacities pertaining to Generator groups and fuel consumption at full load. 3 Table of recommended pipe diameter of fuel installation 21 . • Fuel temperature is a critical factor for proper motor operation. 4.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL WARNINGS atmospheres fuel flow is restricted with increasing of viscosity. This vent output prevents vacuum forming in the tank during fuel consumption. motor output power decreases. Leave a gap as 6% of fuel tank capacity for allowing expansion of fuel at high ambient temperature. steel pipes or flexible hoses can be used for fuel piping.9. it is necessary to apply positive static fuel pressure to fuel pump inlet. Table. expansion or air pressure occurring during the fuel filling to the tank. • Connection pipe from main fuel tank to daily fuel tank should be bigger than or equal to daily tank feeder pipe. In order to reduce vaporization. Since fuel heat more than 71°C decreases heat content per volume because of expansion. FUEL PIPE RECOMMENDATIONS Generator Stand Maximum Maximum Maximum Recommended By Power Length of fuel vertical height number of pipe pipe diameter (inch) (kVA) pipe (m) (m) Fittings Elements 0-800 6 0. A drain valve should be placed the lowest point of fuel tank to discharge water and deposit.9 6 1 1/2" 1500-2200 6 0. • There should not be natural flow from fuel pipes to motor because of gravity when the motor stops. • Do not use galvanized pipe for fuel system. • Do not fill fuel tank completely.9 6 2" • Main fuel tank can be higher or lower than daily fuel tank. flexible fuel hoses must be secured between motor and fuel tank.9 6 1" 800-1500 6 0. So it prevents fuel tank to damage via ensuring accumulating of water and hoses at one point. main fuel tank should not be left at excessive cold atmosphere. Fuel feeder line should take the fuel at least 50 mm above from the bottom of fuel tank and from a point far away from fuel return line. Bottom of fuel tank should have slope. • Using water separator pre-filter in fuel system line will protect injections and fuel pump.3 Fuel channel: Materials conforming with fuel such as Black. vent output should be mounted on the tank. For fuel tank applications to be mounted as per Standby generator groups. In order to avoid leakage and damages caused by motor vibration. Filling line to main fuel tank 3. 19. Electrical fuel transfer pump 11.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Figure 4. Feeder line leading to daily fuel tank 10. 22 Electrical fuel shutoff valve Fuel-liquid accumulation tank Daily fuel tank (in the frame) Fuel level control switches Manual filling and for air Fuel level indication Drain valve Fuel leakage alarm Motor fuel filter Motor fuel pump . Output valve 9. 14. Filling Cabin 2. 20. 16. Drain valve 7. 17. 13. 15. Ventilation shaft 4. 18. Main fuel tank 6.6 Typical general fuel piping mounting of fuel from main fuel tank to daily fuel tank 1. Main fuel tank level indication 5. Fuel-liquid accumulation tank 8. 12. (Figure 4.8) it is placed for protecting motor against hydraulic locking as the same with 2 pieces check valve. proper fuel pressure can not be provided at fuel pump inlet.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Figure 4.7) If fuel tank is raised above about 1. The protection capacity of these valves is from 0 to 1. If fuel level is below 15 cm. Tank mounted far away and at a higher point is shown. In another way. If fuel tank is to be above more than 1. (Figure 4. Maximum fuel level cannot exceed 2 m above crankshaft center and minimum fuel level should be above 15 m from fuel injection pump. If fuel level exceeds 2 m.9 Float tank used with elevated fuel tank 23 . Figure 4.5 m height from Injections.8 Fuel tank and check valve connection put about 1500 mm above from fuel return Figure 4.7 Typical fuel diagram placed below the fuel tank motor Check valves should be used in case of the fuel tank is 2 m above from crankshaft center.9) under motor level fuel tank placed far is shown.5 m height. Figure 4. tank fuel level should not be above the injection and below more than 80 cm from fuel pump. also (Figure 4.5 m float m float tank should be placed. The motor can be damaged.10). While preparing battery wear an overall resistant to acid. filter replacement period and noting sufficiently for oil type used) prolongs motor life and reduces usage cost of motor. sparkle.10 Fuel tank placed below 1500 mm 4. face mask and safety goggles. 4. In case of spilling of battery electrolyte on skin or clothes.11 BATTERIES 4. Exact motor care (oil replacement period.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL While adding water to your radiator.1. Viscosity -temperature diagram: You can control the conformity of oil you use with temperature in your area by means of following chart. clean the spilled area with plenty of pressurized water immediately. ring before using Recommended oil. Using antifreeze water in your motor during summer and winter is very important for motor life and water channels.10. smoking around the batteries. 15W40 Turbo Diesel. The antifreeze is not placed in radiator of your set as factory. 4. Figure 4.exit.1 WELL-KEPT TYPE BATTERIES: WARNINGS Do not allow events to cause combustion such as flame. OIL AND ANTIFREEZE USED IN GENERATOR Lubrication system of diesel motors is one of the most important parts of the motor.10. 24 . Take off jewellery objects in your hand and wrist such as chain. Antifreeze Super 4 season. minimum 35% antifreeze should be added.11. Control whether there is abrasion at v-belt of charging alternator or not and tightness of v-belt regularly.11. Control charging current and electrolyte level with 1 hour internal. do not add distilled water. while disconnecting battery negative terminal should be disconnected from battery at first.1. Note that battery does not remain without charging. If there are no any changes for 1 hour. Electrolyte level must always be over 10 mm from plates. Pouring water to battery and battery maintenance should be performed under open air. Coat battery terminals and connections with Vaseline carefully. 4. If water level of battery has decreased. later charging and if necessary add pure water in such a way that it will be above 10 mm from plates. Dismantle air throw cups.1.4 Hydrometer Test Specific gravity and charging status of sulphuric acid within the battery can be measured using hydrometer. Tight the terminals very well. Fit air throw caps in place. oxidation occurs at lead terminal of battery and connection point. Wait the battery for about 15 minutes. 4. Minimum charging time is 6 hours. This reduces starter capacities of motor. Battery and acid heat should be above 10 °C. As time passes. Oxidation abrades battery lead terminals and prevents charging. Batteries should be place as near as possible to the generator.280 full charged with specific gravity . Then heating will begin at battery eyes (pouches) and gas bubbles will rise out from the surface of electrolyte. Keeping vertical barrel part of hydrometer draw sufficient electrolyte upward. conductive tools. at 20 °C.3 Testing of battery Visual check should be done before testing the battery. Control electrolyte level regularly. There should be free floating within tube. Control the battery with a hydrometer after waiting for minimum 15 minutes. If batteries are placed far away from generator. Then perform connection again and coat with Vaseline.11.1.11.1 Filling of first acidic water of battery Remove the protective cover on the battery cap. Reading should be done at eye level.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. 4. Only use pure water. it causes voltage drop. The evaluation is as the following. Fill the battery until 15 mm above from the top point of plates with clean battery acid whose specific gravity is 1280.11.2 Battery care Maintain clean on the battery and terminals. 1. Control electrolyte level after 2 hours.270 25 1. Do not allow loose connection.1. it has charged. negative terminal should be connected at last. While performing battery connection. Disconnect and clean the oxidation with boiling water. While deciding about cable cut.11. it the distance is very long since current drop will increase very much during demurrage voltage may drop undesired levels. WARNING • Perform electric connections in accordance with relevant electric codes and standards. ( table 4. Cable cross-sections as per current capacities and generator powers are stated below. Except from it.1 Wiring: Electrical connections must be carried out with flexible cables due to the vibration on the Generator.220 specific gravity discharged. To prevent this.P with you can If power is known. load table with more suitable cross-section can be chosen by means of the formula below. Another point that needs to be noted about selection of cable is whether there is load with demurrage (such as electric motor) and distance between load and generator.12 ELECTRICAL CONNECTIONS: Electrical connections and their maintenance must be performed by qualified and experienced authorised service personnel.6) If current is known.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 1. Moreover. these batteries do not require any maintenance. Since it is not possible to produce harmonics and predict the quantity in advance during planning stage of installations.12. = the formula 1.5.2 Uncared type batteries: Make sure that electrical connections are correct and batteries have charge.Δu L. neutral conductors should either be dimensioned as high values or cross-section of neutral conductor should be at leas as phase conductor cross-section. 26 .I. Correctness of all cables must be controlled carefully. = k. 4.Cosø k.150 1. adjacency to other cables will be given. 4.Δu choose load cable withproper crosssectionwith this formula. At low voltage network. tolerances for ambient temperature. cables should be chosen as per TSE or VDE standards.L. installation method. Δu = √3 x L x I ( R Cos + X Sin ) Δu = absolute voltage drop (Volt) L= Length of line (m) I= line current (A) R= resistance of cable (ohm/m) X= resistance of cable (ohm/m) If the distance is short at low voltage Networks. 4. Cables should be located in cable channels and generator should be in accordance with output voltage and current.2201 230 half charged with specific gravity 1. table 4.73. 12. it causes to damage AVR card of the generator.8 power factor. Sometimes. damages being likely to occur in isolation of electrical devices cause metal parts not being related with energy system except main current circuit of devices to be under voltage. 4.4 Power factor: Our generators are configured as per 0. Therefore. 4. If load on a phase is more than another phase. Expected from a good grounding: • It should be continuously and constantly • It should have capacity of bearing failure currents • It should have enough low impedance to keep voltage drop in a limited level. If compensation panels performed for correcting power factor are not configured as per the desired technical features. For this reason. being imbalanced of output voltage between phases and damages sensitive three phase devices connected to the system. isolation is pierced through reaching excessive values of voltage level and being exposed to piercing voltage and it causes these nonconducting parts to be under voltage.12. 4. compensation panel must be deactivated when generator is connected to the load. the power indicated on the label value can be taken into consideration for this power coefficient. Existing distribution system can be arranged again so as to carry out these loading conditions.) k= conductivity (for copper k=56). TT.5 Grounding/grounding conditions: Failures. P = power (W) U = voltage between network phases (V) drawn from the generator increases.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL A= cross-section of line (mm2 ) L= length of line(m) I= line current (A) Δu=% voltage drop (For force line it should not exceed 3%.3 Loading: It is very important to provide giving balanced load to generator while planning of electric distribution panel. If power factor of load is below 0. electric companies in different regions in the world choose transmission and distribution power systems.2 Protection: Distribution system and cables connected to generator are protected with circuit-breaker switch which isolates connection automatically in case of overloading and short circuit. TN and IT systems which are suitable for them.12. • Being low value of ground spread resistance • It can restricted as being low of specific resistance of ground.8 current 27 .12. There are different grounding forms as network varieties of electric companies. Because of this reason. No phase currents should exceed nominal current of generator. 4. Grounding must be performed both for protecting human life and devices. this causes overheating of alternator windings. • Grounding conductor cross section calculation is carried out. • Short circuit current of installations and opening time of protection elements to be connected to the system are determined. processes stated above should be repeated and ground resistance value should be made proper. 28 . The star point of this kind of network is grounded. • The conformity of system in question is searched via calculating step and contact voltage. PE is also connected with grounded part in its star point. Figure 4.5 m long stick The other stick should be penetrated at least 3 m distance forward than the first penetrated stick. namely. • Spread resistance is calculated. voltages against ground of PE or PEN protection lines and connected devices increase. a value which is under the allowed contact voltage can be obtained. In the event of contact between phase-ground.11 TN Type network In projecting of grounding installations: • The place of grounding installations is determined. Distance between stick most used for grounding and the stick used for performed grounding and their length are important. In a grounding used 1. In grounding systems performed with more than one stick grounding the distance of sticks' penetrating should be at least distance of two sticks. The most important subject while grounding in the generator system is that the distance between network grounding area and generator grounding area should be at least 20 m. all conductors and connection points are controlled visually. Before commissioning. Keeping lower than 2 ohm this value of these voltages RB resistance. • Electrode type to be used in the grounding is established.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL TN type Networks are the most widespread used network kind nowadays. desired value. Housing and metal parts of devices are secured to protection conductor PE. Grounding resistance should be Rt < 4 ohm. This distance is for preventing affecting of grounding system each other. • Measurement processes are performed for determining of ground specific resistance. • The accuracy of selection and calculation is examined. If this value can not obtained. 4. Connect Megger between output terminal and ground (frame).DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL operated.7 Insulation test: Insulation test should be carried out in the event that generators purchased from our company waits for prolonged time without 29 CURRENT CAPACITY GROUND AIR 4 4 4 4 4 3 3 3 3 3 x x x x x x x x x x 2. Rotating diode should be shorted or disconnected. Meanwhile. In the event of waiting of generator for prolonged time without operated. Megger of 500 V or a similar measurement tool can be used.5 4 6 10 16 25/16 35/16 50/25 70/35 95/50 36 46 58 77 100 130 155 185 230 275 25 34 44 60 80 105 130 160 200 245 3 3 3 3 x x x x 120/70 150/70 185/70 240/120 315 355 400 465 285 325 370 435 . Grounding cables should meet the standards and have the capacity at least bearing full load current. all connections with the aim o control and automatic voltage regulator connection (AVR) should be isolated. CROSS SECTION mm2 The housing of generator should specially be grounded.12. In case of insulation resistance is less than 1 MΩ. alternator windings should be dried. 4.12. Insulation resistance should be 1 MΩ more than the ground. the ground connection should be flexible. test insulation resistance of windings. In order to prevent breakage to occur due to the vibration.6 Parallel operation: Extra fittings should be secured for operating a Standard generator with other generators or network in parallel way. 4. 4.13 SOUND SILENCER Today controlling noise of generator is getting more and more important. abrasion. 4.14.6/1 KV VDE norms and TSE in case of conditions such a loose nut. To control the sound level of generator.3 other sound silencer: Other equipment such as Sound louvers. 4. please wear headphone. 4.1 Preparation for towing: All connection elements on wrecker and generator should be checked 30 .8). spun metal. standards and other regulations should be observed.3 Parking: Park generator with trailer on a dry ground to be able to bear the weight of generator. weight of trailer may affect the manoeuvre and stopping distance. 4. Necessary hardware and speed limits expresses explicitly in the regulations are included. excessive tear.5 Cable cross sections of proper cables as per current bearing capacity and in accordance with PVC isolated YVV (NYY) 0. 4. etc.14. stone.2 Cabins: Sound isolation cabins reduce loudness level of generator.14. Please control the conditions of all tires.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Table 4. park as crossed to the slope to prevent its being towards downward. Do not allow personnel to travel on the mobile generator. fan silencer. Do not park on a ground that exceeds 15°.13. • Do not allow personnel to stand on the towing bar or between mobile generator and wrecker. • Avoid barriers such as slopped and soft land and hole. sound absorbing walls can be used indoors.14 TOWING OF GENERATOR WITH TRAILER 4.1 Exhaust silencer: Exhaust silencer reduces the sound level coming from the motor (section 4. Control working of all flash lights and headlights. • Make sure that ground behind the mobile generator and under it are clean while manoeuvring backwards. They reduce the loudness level of generator.13. WARNINGS • While towing the generator with trailer all traffic rules.2 Towing: Do not forget that while towing generator with trailer. there are many equipments. crack.13. If it is parked on a slopped ground. WARNINGS • While working at generator site. 6 Cable selection table as per the Generator power DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 31 .Table 4. MAINTENANCE OF GENERATOR A good maintenance program extends service life of generator. 4. If need change to air filter element.8). moisture occurs in the windings.2 Storage of Alternator: During Alternator storage. 32 .15. In order to reduce this moisture. Maintenance and repairs should be performed only by authorised and qualified service personnel. if necessary it must be charged completely. Mixing of 50% antifreeze and 50% water will ensure proper protection in every region. Ensure easy air suction to the generator site somewhere determined. To dry the windings. Do not allow materials such as water. If it is missing. the heater must be activated in every season.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 4. There are block water heater in generators activating automatically. if it is possible heat air. store the generator in a dry place. • Examine motor and generator visually as general. Water level should not ve 30 mm below water filling gland. 4.( section 4. For this reason.15.16 MOTOR BLOCK WATER HEATING For staring up the motor and taking the load on it. Always keep clean ground of Generator. 6. The heater warms roundabout water while generator is not working.15. • Look at the water level via opening radiator cap. When and which maintenance should be performed on the generator is indicated on periodic maintenance chart. CONTROLS AND PROCESSES TO BE CARRIED OUT BEFORE THE STARTING OF THE GENERATOR 4. 4.3 Storage of battery: The battery must be controlled every 8 week while storing.1 Storage of Motor: A motor protection procedure including cleaning motor and protective liquids can be applied.15 STORAGE Long term storage of Motor and alternator may have harmful effects. add some water. • Antifreeze must be available in cooling water of motor even as per the coldest weather conditions of the region. Alternator which has not been used for prolonged time. Periodic maintenance chart is provided with every generator. Generally the generator must always be kept clean.12.Keep opened window louvers of radiator. These effects can be reduced minimum via preparing and storing generator in proper way. fuel and oil to accumulate in and on the generator. 5. • Please check the air filter indication. It is optional in manual generators. must have insulation test. Results of maintenance and repairs having performed should be recorded on Periodic maintenance chart. heater of block (roundabout) water is used. crack. paper. While network voltage is within normal limits. 2. Moreover it stops generator automatically in case of low oil pressure. • Check if there are breaks.1 Operation with DKG 307 Control panel: 1. • Make sure that emergency stop button is not pressed. the generator will step in and start feeding the For controlling and monitoring of operation of generator. if it is obstructed. tools. Turn the automatic transfer device (EOAM 210 FD-FL) located on the front panel of generator to AUTO(automatic). If there is a failure. torn.1. The motor of generator Works for two minutes for its own cooling and stops. Check the oil level of motor with the oil dipstick.OPERATION OF THE GENERATORS 8. They are M 30 and M 40 Model Manual Start control system and P 500 Model or P 2020 Model and P 2010 Full Automatic Start and control Systems.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL • If there is. do not operate the generator until you remove the failure. check the water level on the eye via opening the battery cap. Operation instruction of automatic generator 8. 2. • Check the shroud of radiator air output . 33 . While network voltage is within normal limits. electronic control systems are used. Never add tap water. rag. etc. generator is in standby mode. add some fuel. If it is not enough. In the event of turning of network voltage or entering the usual limits. • Check the fuel level in the daily fuel tank. the system begin to feed from the network in two minutes.1. high motor temperature and other failure conditions. On he motor and alternator. The oil must be close maximum specified line. 8.1. 7. If one of the network phases are cut or network voltage drops excessively. If one of the network phases are cut or network voltage drops excessively. Turn the automatic transfer device (DKG 307) located on the front panel of generator to AUTO(automatic). • Make sure that circuit breaker output switch is on deactivated (OFF) position. remove foreign objects such as keys. If it is insufficient add the proper oil. • Check the battery connection cables. unclog it and move anything obstructing air flow. acidic water or acid to eyes. generator is in standby mode. Fill the missing ones in such a way that pure water will be 1 meter above from the separator. Control panel enables operation of generator.GENERATOR CONTROL SYSTEMS 8. monitoring of working condition and output voltage. the generator will step in and start feeding the installation. Tighten the loose battery post with wrench and keep clean the posts. One of the Standard control systems can be used as per the requirement of Generator. looseness.2 Operation with EOAM 210FD-FL Control panel: 1. • If you use well-kept type battery. leakage. stopping it. 7. Check amperage and voltage on the phases via using amper meter and voltmeter commutator. 8. 2. Turn the automatic transfer device (AMF 4. After starting of motor. 6. In the event of turning of network voltage or entering the usual limits. . Then turn starter switch to 'START' position (like starting up a car). Operate generator at idle position for 1 minute to cool. 10. let starter switch. If one of the network phases are cut or network voltage drops excessively. Turn inverter switch to “NETWORK” when the network returns. 8. the generator will step in and start feeding the installation in 7-8 seconds. While network voltage is within normal limits. the system begin to feed from the network in two minutes.1) 2. 8. The motor of generator Works for two minutes for its own cooling and stops. 11. Meanwhile. During this period the motor will get heated.1 34 .3 Points to be noted while starting up: It is important that load distribution on phases is balanced for both manual and automatic remote control generator so as to ensure Figure 8. oil pressure failure and charge warning light will go on. Turn inverter switch from “NETWORK” position to 'GENERATOR' position. The motor of generator Works for one minute for its own cooling and stops.2. Then turn starter switch to “0” position. Turn main switch to '1' position. 3. Motor of Generator will start working. Check whether warning lights on the panel go on and values on the indications are normal or not.0 Control panel: 1. 4. generator is in standby mode.0) located on the front panel of generator to AUTO(automatic).DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 8. the system begin to feed from the network in a minute. Engage receivers one by one. Operate the generator in idling status for about 1 minute. 9. Turn contact switch from '0' position to '1' position.1. Meanwhile. 5. receivers (loads) on the installation must be turned off. In the event of turning of network voltage or entering the usual limits. 1. (Figure 8. 12.3 Operation with AMF 4. Operation instruction of manuel generator installation in 7-8 seconds. Programmed parameters are stored on a nondeletable memory in such a way that they will not be affected by power cut. It is the user's responsibility that load distribution among phases will remain between -/+ 15% tolerance values.Program parameters.W-V. 7 segment LED type indications on the device. MEASURED PARAMETERS Voltages between Network Phase-Neutral (R-N.T-N) Voltages between Network Phase-Phase (R-S.S-T) Voltages between Generator Phase-Neutral (U-N.1 35 . Figure 9. INTRODUCTION AND OPERATING INSTRUCTIONS OF AUTOMATIC TRANSFER DEVICES: 9.R-T. 9.Statistical counters. The following are read on these indications : .W-N) Voltages between Generator Phase-Phase (U-V.S-N.1 DKG 307 Automatic Transfer Device: The device is control and protection panel to be designed for used in the generators.Service counters. .V-N. .Measured parameters.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL operation of generator without problems. It shows values that it has measured on the screen. . Failures resulting from insufficient and/or deficient maintenance are not within the scope of guarantee.U-W) Generator phase currents (I) Generator phase voltage (V) Generator phase power (W) Generator frequency (Hz) Generator total active power (kW) Generator power coefficient (Cos ’) battery voltage Temperature of cooling water Oil pressure Introduction: There are 3 pieces. LED on the upper side lights. the generator changes to automatic operation mode and LED on the upper side lights. generator operates automatically when network electricity is cut and when it returns.1 Digital Indications: Value of Program parameter is read o this indication during program position.Voltages between (U-V-W) generator phase-neutral . When Generator is operated with this key. (3) MULTI FUNCTIONAL INDICATION: Following values can be read on this indication pressing MENU key.1. following values can be read separately: . (R) phase voltage . While this key is pressed. When this key is pressed. (6) LAMP TEST: Lamp test. When pressed this key.Generator frequency (Hz) .During operation from Generator. (PGM) is read. the name of counter is read on this indication.battery voltage (V DC) (9) TEST: Test key is for operating generator for the purpose of test when there is network electricity.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 9. (8) OFF: It is used for switching off generator whose switch off key is in operation.Voltages between (RS-ST-TR) network phase -phase .Temperature of cooling liquid (∞C) . .Voltages between (R-S-T) network phase-neutral . generator does not step in automatically. 36 . If MENU key is held pressing for one second.Generator cos ’ . Current transformers between 10/5A and 9000/5A can be used by means of programming. By pressing MENU button. (1) VOLTAGE INDICATION: Following values can be read on this indication: (4)ALARM MUTE: Alarm silencing.oil pressure (bar) .Generator active power (KW) . At programming location.Voltages between (UV-VW-WU) generator phase-phase If service counters are read. it stops. (2) CURRENT INDICATION: Measured over current transformer phase currents can be read on this indication.During operation from Network. automatic control unit does not command connectors.(U) phase voltage (5) MENU: Browsing of measured values of indications can be done pressing MENU key. (7) AUTO: When pressed Auto key. Program number is read here during program position. .1. service counters are accessed. OVERLOAD LED: It occurs exceeding programmed limits of one of the generator phase current or active power of generator. next coming alarms and warnings are not included in the process.If there is any alarm. this error is not controlled. HEAT LED: It occurs when a signal comes from excessive temperature contact or when measure value at temperature switch exceeds the adjusted limit. (11) ALARM LEDs: Alarms Works as per the first coming principle. according to this.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL (10) LOAD TEST: Load test is adjusted by authorised service dependent on the request. VOLTAGE LED: It occurs in the event of exceeding limits of at least one of U-V-W phase voltages. any of working patterns is pressed (AUTO-OFFTEST-LOAD TEST) LEVEL LED: It is available with some models. . next coming warnings are not considered. (over speed /under speed) SPARE LED: It occurs when the signal comes from any of spare failure contacts. oil pressure switch may be defective. FREQUENCY LED: It occurs resulting from exceeding programmed limits of Generator circuit. EMERGENCY STOP LED: It occurs when he signal comes from emergency stop contact. SERVICE TIME LED: This LED is used for helping to perform periodic service of generator regularly. For locking alarms.If there is any warning. it occurs. alarm lights remains lighting even if the reason of alarm has been eliminated and they prevent generator's working. BATTERY LED: It occurs when battery voltages exceeds programmed levels or decreases below them. Periodic service is carried out when a certain motor time 37 . OIL LED: It goes on when motor oil pressure goes down a dangerous level. STOPPING ERROR LED: If motor does not stop at the end of adjusted stop period. this alarm occurs. During the starter. To delete alarms. If this LED goes on while the generator is not working. CHARGE LED: It lights up in case of failure of charge alternator or belt breaking. RECTIFIER FAILURE LED: It occurs when signal comes from rectifier failure inlet. Alarms can be of locking or non locking type as per the programming. . STARTER FAILURE LED: If generator does not operate at the end of programmed starter number. 2 38 . .Group 2:Mimic diagram: it shows status of Network and generator voltages and connectors. .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL has completed.1.S-N. Engine RPM Real Time Error mesages Battery voltage Coolant temperature Oil pressure 9.S-T) Voltages between Generator Phase-Neutral (U-N.W-N) Voltages between Generator Phase-Phase (U-V.R-T.Group 1: Working way: It shows function of the Generator.Group 4: unit: It indicates the unit of value shown on the lower indication.U-W) Generator phase currents (I) Generator phase voltages (V) Generator phase power (W) Generator frequency (Hz) Generator kVAh Generator Kwh Generator kVAr Charge generator voltage EOAM 210 FD Figure 9. MEASURED PARAMETERS Voltages between Network Phase-Neutral (R-N. . It show values that it has measured on the display.Group 3: Warnings and alarms: It shows abnormal conditions experienced during working.W-V. Generator power factor (pF) LED indications: There are 29 LEDs within 4 group on the device. .V-N.T-N) Voltages between Network Phase-Phase (R-S.2 EOAM 210 FD-FL Automatic Transfer Device: The device is a control and protection panel designed to be used in automatic generators. Programmed parameters are stored on a nondeletable memory in such a way that they will not be affected by power cut. AUTO and TEST modes. (15) This button indicates that Mains or Generator voltage is displayed voltages. only operative when manuel mode is selected. It's colour is green. only operative when manuel mode is selected. (23) When this button is pressed. (27) The LAMP TEST button illuminates all LED indicators and display segments. It's colour is green. (3) The green LED indicates that Mains voltage and frequency is within limits and is ready to take over the load. (12) The red LED shows that the unit is in the AUTO mode.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Introduction: (1) The red LED indicates that Mains voltage is displayed. (2) The red LED indicates that Generator voltage is displayed. (17) This button closes the mains contactor. (4) The LED shows that the load is connected to the mains. only operative when manuel mode is selected. (5) The LED shows that the load is supplied from the generator. this LED indicates that the engine has starting up or is running. AUTO and TEST modes. only operative when manuel mode is selected. (28) This button will silence the alarm horn after a failure has been 39 . (10) The red LED illuminates only when the unit in the programming mode. (9) In the MAN. (19) This button closes the generator contactor. (13) The red LED shows that the unit is in the TEST mode. (22) The STOP button is used for stopping the engine when the unit is in the manuel mode. the unit goes into its programming mode. (14) The red LED shows that the unit is in the MANUEL mode. (16) This button selects either Phase-Neutral or Phase-Phase voltages. (7) The green LED indicates that the engine has started and is running. this LED indicates that the engine has stopping or stopped. (11) The red LED shows that the unit is in the OFF mode. (8) In the MAN. (21) The START button is used for starting the engine when the unit is in manuel mode. (20) This button opens the generator contactor. (18) This button opens the mains contactor. (6) The green LED indicates that Generator voltage are within limits and is ready to take over the load. U-W) Generator phase currents) Generator phase voltages(V) Generator phase power (W) Generator frequency (Hz) battery voltage temperature of cooling water oil pressure (33) The MANUEL button is used for changing operating mode of the unit to the MANUEL mode. (32) The TEST button is used for changing operating mode of the unit to the TEST mode. When motor is not starting under cold weather conditions. (30) The OFF button is used for changing operating mode of the unit to the OFF mode. (39) Failure indicators.W-N) Voltages between Generator Phase-Phase (U-V. transfers load between network and generator and controls of failure. 9.T-N) Voltages between Network Phase-Phase (R-S.S-N. It operates only in manual mode and when motor stops. It a microprocessor-controlled device that monitors one or three-phase network voltage.W-V. (1)pre-heating: (38) The display shows Mains or Generator voltages. Introduction: (35-36-37) The display shows LOAD Amp.0 Automatic Transfer Device: (START) Starting button: It is used for providing starting for motor. 98 parameters related with the operation of the device are adjusted digitally and stored in the memory separately. (31) The AUTO button is used for changing operating mode of the unit to the AUTO mode.V-N.1. it is tried to start motor via performing pre-heating. When holding pressed of Menu key for 3 sn. 40 . MEASURED PARAMETERS (29) This button will reset the controller after a failure has been detected. Voltages between Network Phase-Neutral (R-N. “Str” is written on the screen during the starting time of panel.R-T.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL detected. It operates when only in manual mode and motor is stopping.S-T) Voltages between generator Phase-Neutral (U-N.3 AMF 4. it takes generator to manual mode and begins to cooling if generator has taken load before of if the load has not been taken it starts stopping process. (5) Network Status LED. During cooling. it means delay times when network passes from normal statutes to network failure or from failure to normal status. To be turned off contactor of network needs to be on. (6) Failure LEDs: Detailed information about these failures are provided in the following sections. it means that network voltage has exceeded the limits indicated with parameters. Figure 9. : When it does not go on. (4) Generator Status LED: When it goes off it means that generator is stable. 41 .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL (3) Network contactor: It controls the contactor that enables the load to be fed by the network. It is not matter in which mode is used. (7) Analog oil pressure and over heating indications: In this part. if stop key is pressed done more generator will stop. If LED is flashing.For overheating. When it goes on it means that network is within normal values. when it is pressed. it means that generator is in the period of cooling and stopping. for oil pressure the dial can go the highest value that the switch can be read from starting low oil pressure failure level adjusted in parameters. If LED is flashing. values read by indication points of oil pressure and overheating switches are printed on the screen as bar graphics in such a way that the user can easily see.3 (STOP) Stopping button: It is used for the purpose of stopping Motor. When it goes on it means that generator is working. NOTE: Generator contactor is locked electrically with network contactor. If LED is going on it means that contactor is off and load is feeding from network. (2) Generator Contactor: It provides transferring of produced energy to the load after Generator has began to work. The status of contactor is indicated via LED on it. the dial starts from 50 C to 100 C. Both of these contactors can not be turned off at the same time. contactor is off and it means that load is feeding from generator. If LED is going on. At the second pressing failure is deleted. If the value entered during changing of any parameter in parameter menu. menu key should be pressed while LED next to the indication is flashing. every order of Parameter value can be adjusted the desired number with the help of up/down keys. LED next to the indication in the 42 . it is cancelled via this key. when menu key is pressed for the first time LED next to the indication in the selection mode will start flashing. Esc Key: This button has many functions. Under normal operating status. It indicates that whether measurement values shown via LEDs next to it belongs to network 'MA‹NS' or generator 'GEN'. Overheating Failure: (+. It is used for exiting from parameter menu. horn is silenced at the first pressing. Low High speed Voltage failure: This failure occurs when electricity produced by the alternator goes out of the voltage values. automatic (letter A) or test mode via three keys located at the right of Panel.-) Up. selection mode will start flashing when these keys are pressed for the first time. Low High speed failure: This failure occurs when alternator goes out of limits of frequency of electricity that it has produced. To change th indication in the selection mode. After switching one of the parameters on the parameter menu via pressing “ENTER” key to adjustment mode. Then value to be shown on this indication will be changed via down/up keys.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL (8) Measurement mode selection button: It selects if frequency and voltage values shown on 2 screens will belong to generator or network. (9) Selection of working mode button: The system can be operated as manual (hand symbol). It provides selection of values to be shown on the indications at the left side of panel. In the event of failure. It provides entering parameter menu. The mode of system can be seen via LED next to it. it needs to be held pressed for 3 seconds. Down keys: Under normal operating condition. When it is pressed for the second time the value of indication is changed. FAILURE AND WARNINGS: (ENTER) Menu Key: This button has many functions. For this process. It is used for changing any values on the parameter menu. this failure occurs when the inlet is active. Low oil pressure Failure: (23) Working hour: It shows how many hours your set has worked. It should not be used except emergency. In the event that emergency stop button is pressed A3 is written on the indication and AUX failure LED goes on. NOTE: The button is located on the cabin at sets with cabin. Active functions in the system is emergency stop inlet and water level failure inlet. Devices of control panel: (22) Charge warning lamp: When lamp turns on it means that battery charge alternator charges less than normal and there is a problem. if oil pressure. So. Resetting process is done by the service. getting back should be provided via turning slightly right. Stop working Failure: It means that when this failure occurs generator has not been starts up or stopped. charge or low high voltage LED go on together with stop working failure LED. Charge Failure: This failure occurs in the event that voltage in the end ›f charge failure of charge alternator drops. oil pressure. 43 . Battery Voltage low high Failure: It occurs when battery voltage goes down or up adjusted limits. the indication writes A4 and AUX LED goes on.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Over current Failure: Periodic service time warning: This warning is provided when adjusted after resetting of service time periodic service time has passed. the user can understand generator does not work due to the signals. During the starting up generator. In case of a failure in radiator water level. Spare failure LED: If functions of spare inlet are selected as yellow or red. charge or alternator voltage are perceived. (24) emergency Stop Button: It provides your set to be stopped immediately in case of emergency. After performing stopping via pressing the button. The panel should be located in place which is clean. Figure 9. 1. 2. Maximum difference between phases must be 15%. Connecting of generator after the meter should be noted. current bearing capacities of force cables to be used for generators are indicated on table 4. 5. there should be enough working space around the panel. there are two cable entries to the panel. One of them is network entry for the control of network and the other one is the output of generator.6. Network line from meter output or if any network line from compensation panel are transmitted to the receiver over network. LOCATION AND INSTALLATION OF FORCE PANEL The points to be noted during the installation ot force panel (transfer switch) are stated below. operation connection of generator must be performed correctly. wellventilating and far away from excessive heat. 3.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 10.1. Mount the force panel as close as main distribution panel. 6. The pattern of this connection is shown at Figure 10. dry. Values of currents drawn from generator should be distributed to three phases equally as much as possible. 4. In order to function properly.4 44 . Covers of panel must be easily opened and panel should be easily interfered. CAUSE: a)Loss of residual magnetism at Stator windings. -Test diodes one by one with diode parts of AVO meter and replace Figure 10. contact the same poles of dry battery of 9. . If Alternator warning is of winding.1 45 .5 V to + and .poles of connector at the connector poles numbered 1 and 4 for 5 seconds. c)There is disconnection at warning button. d) There is failures at rotating diode.poles of connector at the connector poles numbered 2 and 3 for 5 seconds.5 V to + and . contact the same poles of dry battery of 9. b)There are loose contact at panel and connector connections.control all connections especially alternator series connector connections. .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 11. -Opening cover of panel.If alternator warning is without winding. control whether cable ends have pulled out or not and in the same manner. ALTERNATOR FAILURES AND REPAIR FAILURE: Alternator does not produce voltage. control whether connector ends have pulled out or not. 4-Voltage of Generator is very high. CAUSE: CAUSE: a)Regulator card is defective. a)There are motors rotating reversely in the circuit. -control connector connections.Increase the cycle of drive machine to the nominal. Replace the defective ones. if voltage decreases as loaded. -change the card that does not perform regulation. After this adjustment. b) Cycle drop of drive machine is very much. replace the card. -Replace the location of Generator output cables. CAUSE: f)Regulator card is defective. -Control the ends of potentiometer. -Control diodes with AVO meter. . b)There is disconnection at Voltage adjustment potentiometer. e)Cycle of drive machine is very low.Adjust regulator potentiometer and output voltage to 400 V at idling. -Control the power of drive machine. c) It is loaded over Alternator power. a)One of ends of regulator experiencing phase is disconnected. . -do not load over nominal. FAILURE: 5-Voltage is not read from one or two phases. FAILURE: FAILURE: 2-Voltage drops as Alternator is being loaded. -Replace the card that does not perform regulation. d)Rotating diodes are defective. c)Regulator card is defective. FAILURE: 3-Voltage is increasing as the Alternator is loaded. 46 .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL damaged diodes. CAUSE a)There are disconnections at the end of Voltage control commutator. If there is resistance difference. -operate at Nominal load. Control short-circuit or disconnection among windings. it means that there is short-circuit. remove the star connection bridge. b)There are short-circuit at windings. b)There may be short-circuit among windings. CAUSE: Starter motor revolves diesel slowly • Battery has no charge • Contact of battery cables is poor • Starter motor is defective • Viscosity grade of lubricating oil is wrong a)Generator is loaded over nominal. FAILURE: 12. Oil pressure is very low • Viscosity grade of oil is wrong • There is not enough oil in the crankcase • Pressure indication is defective • Oil filter is defective FAILURE: 7-There is undulation at output voltage of Generator. -Perform short-circuit control among windings at connector box. CAUSE: 47 . FAILURES OF DIESEL MOTOR AND REPAIRS 6-Windings heat excessively. b)There is disconnection at Stator windings. c)One or more of bridge diodes are defective. . . Possible motor failures and their causes are stated below. -Control the ends of commutator. -Control windings with AVO meter via opening connector box.opening cover of connector box.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL a)Regulator card does not perform regulation function.Replace the regulator card. Fuel tank is empty Fuel pipe is clogged Fuel control solenoid is defective Fuel filter is dirty Heater does not function Exhaust pipe is clogged Third-class fuel Fuel tank ventilation is clogged Fuel leading pump is defective Injections are defective or their adjustment is out of order Oil sensor connection is defective Fuel pipe is clogged Fuel filter is dirty Air filter is dirty There is air in Fuel system Third class fuel Exhaust pipe is clogged Fuel leading pipe is defective Governor is defective Motor heat is high Motor heat is low Injections are defective or their adjustment is out of order Fuel tank ventilation is clogged Fuel advance adjustment out of order Motor functions irregularly • • • • • • Oil pressure is very high • Viscosity grade of oil is wrong 48 Fuel pipe is clogged Fuel governor is defective Fuel filter is dirty Fuel pump is defective Air filter is dirty There is air at fuel system .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL • Oil pressure indication is defective Blue or white exhaust fume • • • • • Motor does not provide enough power Viscosity grade of oil is wrong Heater is defective Diesel motor is cold Valve adjustment out of order Fuel advance adjustment out of order • • • • • • • • • • • • • Diesel motor Works hard or does not work • • • • • • • • • • • • Starter motor revolves diesel hard. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL • • • • • • • • • • • • • • Injections are defective or their adjustment is out of order Fuel tank ventilation is clogged Valve adjustment is out of order Motor heat is very high Heater system is defective There is resistance in the action of Fuel governor Motor heat is very high • • • • • • • • • Fuel filter is dirty There is air at fuel system Fuel pump defective Motor heat is very low Valve adjustment is wrong Injections are defective or their adjustment is out of order Heater is defective Oil sensor or its connection is defective There is knocking in the motor Exhaust pipe is clogged Cooling fan is damaged Radiator core is dirty or pipe is clogged Cooling system is insufficient Air filter or pipe is clogged Injections are defective or their adjustment is out of order Heater system is defective The oil level in the crankcase is low Water to cool level is insufficient • • • • • • Valve adjustment is out of order Injector is defective or its adjustment is out of order There is failure at Fuel pump Third-class fuel Motor heat is very low Heater system is defective Fuel consumption is very much Crankcase pressure is high • • • • • • • • Crankcase ventilation pipe is clogged • Valve adjustment out of order Ignition (in case of not working) • Fuel pipe is clogged 49 Air filter is dirty Fuel is third-class Exhaust pipe is clogged Heater system is defective Valve adjustments are wrong Motor temperature is very low Injections are defective or their adjustment is out of order . DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL Exhaust fume is black • • • • • • • Air filter is dirty Motor is overloaded Fuel is third-class Exhaust pipe is clogged Motor heat is very low Valve adjustment is out of order Injection is defective or its adjustment is out of order Vibrating operation • • • • Fan is damaged Fuel governor has difficulty in its movements Injection is defective or its adjustment is out of order Motor heat is very low Motor stops after functioning • • • • • There is air at fuel system Fuel filter is dirty Air filter or suction system is clogged Oil sensor or its connection is defective Stop solenoid conservative bobbin is defective 50 . PERIODIC MAINTENANCE INSTRUCTION 51 .DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL 13. WHEN GENERATOR IS IDLED. IF NOT. THE WARRANY IS VALID ONLY FOR SPARE PARTS AND THE PERIOD IS FOR 1 YEAR OR 1000 HOURS RUNNING TIME FROM THE DATE OF DISPATCH.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL DEAR EMSA GENERATOR USER. OIL SELECTION OF MOTOR SHOULD BE IN ACCORDANCE WITH THE ONE STATED IN THE MANUAL. 7. OTHERWISE. STARTING AND STOPPING MUST BE PERFORMED AFTER LEAVING OF LOAD. INSTALLATION OF THE GENERATOR MUST BE PERFORMED AS STATED IN THE MANUAL. FUNCTION PROPERLY AND BE LONG-LIVED. LOW AND HIGH VOLTAGE TO OCCUR IN THE NETWORK CONTACTOR USED IN AUTOMATIC GENERATORS. THIS CAUSES DAMAGES IN VOLTAGE REGULATOR. EXCESSIVE ADDITION OF ACID. 3. FAILURES TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. OTHERWISE. PLEASE NOTE FOLLOWING POINTS TO ENSURE THAT YOUR GENERATOR WILL NOT BE VOID OF GUARANTEE BEFORE ITS TIME. FAILURES RESULTING FROM NOT HAVING PERFORMED PERIODIC MAINTENANCE ARE NOT WITHIN THE SCOPE OF GUARANTEE. THE WARRANTY IS INVALID IN CASE OF GENERATOR IS INTERFERED BY OTHER PERSON THAN EMSA AUTHORISED SERVICES FOR ANY REASONS. 1. THESE CONDITIONS ARE NOT UNDER WARRANTY. PROBLEMS TO OCCUR WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. CHECKS AND MAINTENANCE STATED ON THE PERIODIC MAINTENANCE CHART MUST BE PERFORMED ON TIME AND COMPLETELY. OUR COMPANY IS NOT RESPONSIBLE FOR FAILURES RESULTING FROM OVER CURRENT. 6. 2. TRANSFORMER AND DIODES. DO NOT START UP OR STOP DIESEL MOTOR WHEN GENERATOR IS UNDER LOAD IN MANUAL GENERATORS. BATTERIES DO NOT REMAIN UNDER WARRANTY IN CASE OF BREAKING. COMPRESSIONS MAY OCCUR IN THE VALVES. 5. THE CUSTOMER WILL BE RESPONSIBLE FOR FAILURES RESULTING FROM DIRTY AND WATERY FUEL. 4. 52 . HARDENING DUE TO NOT CHARGING. TRANSACTIONS PERFORMED WHEN GUARANTEE DOCUMENT OR INVOICE ARE NOT PRESENTED WILL NOT BE INCLUDED WITHIN THE SCOPE OF GUARANTEE. 8. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL RESPONSIBILITIES OF CUSTOMER 1. If the generators purchased are not commissioned within 2 months. In the event of losing maintenance manual and chart in question the customer is responsible for obtaining them again. ceilings. In case of requesting to change the location where the first start has been carried out. Entire maintenance indicated on periodic maintenance chart of all our generators should be performed by Emsa Generator authorised services within the guarantee period. 53 . Overtime pay of a service personnel who furnishes guarantee service if requested by the customer. unloading (after the delivery of on the track until commissioning (start) process) will be the responsibility of the customer. it must be commissioned by Emsa Generator authorised services via controlling for continuance of guarantee period and efficient working of generator. 8. You may obtain information about storage conditions of your generator from Emsa Generator Authorised services. decks and structures like these. 9. Commissioning process performed via controlling working conditions of generator (installation. misusing. Prices resulting from entries built for accessing the generator. For deliveries on the trucks. failures and problems except manufacturing defect. Such an interference will cause to invalidate of generator spare part guarantee. exhaust output. fuel channel. bases. Maintaining of the generator under proper conditions including failures resulting from negligence. The customer of EMSA GENERATOR must not allow unauthorised service or person except services of Emsa Generator to interfere with his generator under spare part warranty. since working conditions of generator dependent on the environment will change. ventilation. The customer will cover prices for repairing of all maintenance. 6. walls. mounting. maintaining of the generator under proper conditions including shipping responsibility. It is imperative to get Emsa Generator performed the storage processes (conservation) of a generator within the guarantee period. 5. electrical connections. unloading responsibility (after the delivery of on the track until commissioning (start) process) will be the responsibility of the customer. If the customer performs start process himself or gets it performed by another service. Commissioning of generators purchased must be performed by Emsa Generator authorised services. barriers. 3. this causes invalidation of guarantee. etc. parapets. Maintenance chart and maintenance booklets pertaining to the generator are handed over the customer with the generator. 4. 2. cable cross sections.) is valid only for the location where commissioning has been performed and point where electrical connections have been carried out. will be paid by the customer. 7. it can be waited provided that storage conditions related with the generator in question are ensured. flood and similar natural disaster. 16. 14. the spare part guarantee will be invalidated. 17. 15. The damages resulting from not added of chemicals that need to be added so as to prevent pitting in cooling systems. all damages will be under the responsibility of the customer. In the event of changing operation place of a generator being under guarantee. Failures to occur in the generator resulting from the environmental effects are not under spare part warranty. Network low and high limits for our all generators are determined on the basis of values that our generator and plant that the customer have will function well. This is at the same time responsibility of the customer. wrenches or taking of generator completely or securing of the generator will be met by the customer. 18. For all our generators under spare part warranty. to ensure the continuance of the guarantee commissioning process should be demanded from Emsa Generator authorised services after the installation of generator in the new place. Emsa Generator is not responsible for the failures resulting from excessive current drawing than generator nominal current over the network contactor selected proper for the power of generator. these changes can be performed provided that a report will be written that shows failures resulting from these changes will be the responsibity of customer. 54 . earthquake. additional control unit. 13. cylinder liner or block. The customer is obliged to show the guarantee certificate and start form of the generator to the service authorities to obtain guarantee service. ) are carried out without the approval of Emsa Generator.Addition hardware and projects except original equipment and Project can not be applied to generators purchased within the spare part guarantee period. In the event of requesting of customer to change Network voltage limits. For example. The customer is responsible for ensuring dimensions of generator room to conform with the norms. ramps or similars. etc. 10. these documents in question should be maintained in the generator room and in an easy-to reach place. Place changing and commissioning to be carried out by the unauthorised person cause the generator to be excluded from the guarantee. Thus. transfer panel. 19. The price of second commissioning will be covered by the customer. original spare parts of Emsa Generator should be used. erosion and deposit will be the responsibility of the customer. sufficient ventilation. In the event of not using original parts. 20. The customer has the right to ask and inquire the authority of the personnel coming for the service. and exhaust output.DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL hired hoists or similars. If additional Works planned to perform (synchronous. 12. DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL NOTES 55 . DIESEL GENERATOR GROUP OPERATING & MAINTENANCE MANUAL NOTES 56 .
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