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(The following suggestions shall help you to achieve optimum performance from the D.G. Set.)
Note: 1. 2. Please always sign the report made by our Service Engineer. Warranty is applicable for two years subject to use of Kirloskar KOil, Kirloskar genuine filters, K cool super plus and services sourced through KOEL authorized Service Dealer.
SELECTION OF SITE
Proper space should be there for placement and opening of doors of the Silent DG set. should be atleast 1.5 meter free space around the DG set for There proper operation and maintenance. should be cross ventilation of air to ensure proper cooling of DG There set. Exhaust gases and hot air discharge should not re-circulate inside the acoustic enclosure (canopy). should be no restriction for fresh air suction and hot air discharge. There If 2 DG sets are installed at the site, ensure that hot air outlet of the one DG set does not become the fresh air intake of the 2nd DG set. height shelter for the Silent DG Set should be avoided. It should A low not obstruct the hot air outlet. preferable to install the DG set in an open area. No shade (roof) is It is required over it. However, if the AMF Panel is outside the Acoustic Enclosure, then a shelter is recommended for the Panel. Roof Top Installation, ensure that the civil structure is capable to For bear the static and dynamic load of DG set. The load of the Silent DG set should be borne by Columns and Beams of the building. Proper space should be there for Earthing. If there are no space constraints, the DG set should be placed near the distribution panel. DG set should be located away from polluted surroundings such as The corrosive fumes, cement dust, fibres, cotton and toxic chemicals to avoid overheating of the D.G. Set.
NOT TO SCALE
IF IN DOUBT ASK
50
50
DG SET
TOP VIEW
SIZE OF BAR
UP TO 82.5 KVA
2 100 KVA TO 200 KVA
10MM DIA
12MM DIA
16MM DIA
200
RCC 1:2:4
450
SERVICED
FRONT VIEW
PCC
TITLE
PART NAME
DRAWN BY
CHECKED BY
DRG. NO.
DATE
KIRLOSKAR ENGINE
RF-7-06
7/02/06
*THIS IS ONLY A REFERENCE DRAWING. KINDLY CONSULT YOUR CIVIL ENGR / CONSULTANT FOR MAKING FOUNDATION
APPROVED BY
EARTHING SYSTEM
Earthing system is required for the protection of equipment and human An being, as per Indian electricity Rules 1956. Separate earth should be used for body and neutral earthing.
4 Nos. earthing pits are required for 3 phase DG set, 2 each for neutral & body. 2 Nos. earthing pits are required for single phase DG set, 1 each for neutral & body. min. distance between 2 earthing pits should be 2.0 meters. The An earth pit cover should be provided. A watering pipe of 19mm with a funnel should be provided for each pit, wherever depth of the earthing pit is not at water level. Earthing system should be checked with meagre and maximum 1.0 om resistance should be ensured. earthing plate/pipe and strip size should be selected as per the rating of The the DG set. Description Copper Strip 25x3 GI Strip 25x6 Description Copper Strip 25x6 GI Strip 50x6 Unit
mm mm
Unit
mm mm
EXHAUST PIPING
The exhaust system must be designed to keep the resistance to hot gases (back pressure) as low as possible and load of the extended exhaust pipe/silencer should not be on the engine manifold. The Following may please be noted. should not be any load or stress on the exhaust bellow. There A uniform gap has to be maintained between bellow flange and exhaust pipe flange. should be proper support for the exhaust pipe. There should be extended through proper flanges only. Pipes bends should be avoided. Short use proper size M.S. pipes (G.I pipe and bend should not be used in Always exhaust piping). Air cooled Description Exhaust Pipe Dia Water cooled R-Series Description Exhaust Pipe Dia SL Series Description Exhaust Pipe Dia K Series Description Exhaust Pipe Dia Unit mm 275 KVA 125 320 KVA 150 400 KVA - 625 KVA 2 x 150 Unit mm 140 KVA 250 KVA 125 Unit mm 15 KVA 35 KVA 63 40 KVA 62.5 KVA 76 75 KVA 100 KVA 82.5 KVA 125 KVA100 125 Unit
mm
15 KVA35 KVA
63
75 KVA
100
FUEL PIPING
A supply and return fuel pipe is required in each DG set . upto 200 KVA are provided with fuel tanks inside the acoustic SDGs enclosure. 200 KVA, the fuel tank is outside the acoustic enclosure. Above For fuel tank inside the enclosure, fuel piping is done by the
manufacturer/supplier. However, for Fuel Tank outside the enclosure, fuel piping is to be done by the customer. of the fuel piping should be 12mm upto 250 KVA DG set. Size Class M.S. pipe (19 mm - 25mm I.D.) is recommended For fuel B/C piping above 250 KVA DG sets. pipe should be used with proper welded joints. MS valve and flange should be used at supply line to engine near fuel Stop tank (for Fuel Tank mounted outside).
GI pipes in fuel piping of DG set. Never use should be welded and never threaded. Joints Pipe should be above ground level with proper MS support. should be tested for any seepage or leakage. All joints KVA and above DG sets, Fuel Tank height should be such that For 320 lowest level of Fuel Tank is above Diesel pre-filter height.
CABLING
It has been our experience that most electrical failures are caused by overheating due to loose thimbling or undersize cables. Please use cable of correct size to carry full load current and thimble of correct size for cable termination. At no time, loose wires should be tightened on to terminal/busher with bolts. Crimping should be done with proper crimping tool.
CABLE SIZE
For 3 Phase
KVA Al. Cable Size 3.5 core sq. mm 15 20/30 35/45 50 62.5 82.5 100 125
1x16
1x25
1x25
1x35
1x50
1x70
1x95
1x120
Copper Cable Size 3.5 core sq. mm KVA Al. Cable Size 3.5 core sq. mm
1x150
185
240
300
2x185
70 mm2
95 mm2
120 mm2
150 mm2
240 mm2
For 1 Phase
KVA 15 20 30-35 40 50 62.5 70
25
25
50
70
95 or 2x50 50 50
150
15 16
20 16
30-35 25
40 35
70 70
Note : a. Correct size cable Glands should always be used for holding the cable. b. Control wiring should always be done with 2.5 sq.mm copper cable. c. Form 320 KVA to 600 KVA bus bar terminal box will be provided by customer.
AIR COOLED
Engine Model Rating Lts. HA294 4.5 HA394 9 HA494 11 HA494TC 11 HA694 13.5 HA694TC 13.5
RV2
RV3
2R 1040
6R1080T
6R1080TA
5.4
8.5
8.5
9.5
11
13
15
15
SL90TA 22.5
6K12 TA 23
8K15 TA 28
10K18 TA 35
12K22 TA 40
Note: Recommended lube oil / filters change interval after 50 Hours First, that, every 250 hours After
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Air cleaner mounting Air cleaner cleanliness Air cleaner clamps 7 Hoses Grade & specs of oil used Lub oil level & positioning of oil filter Check lub oil safety All Nuts & Bolts Battery condition Battery Terminal/Leans Electrolyte level Fuel Filter V Belt for charging alternator V Belt tension Water level in the Radiator Check water temp. sefety Wiring (Engine/Panel) Check all wires tightening Alternator back cover Cable termination Canopy door alignment Canopy door hinge operation
Fitted/Not fitted Clean/dirty/replaced (Dry or oil) Cracked/normal/ not clamped ........ as per manufacture's recommendation OK/Not OK OK/Not OK Proper/Tightened Charged/Discharged Proper/damaged/ replaced High/Medium/Low Proper/to be replaced Proper/Tightened/not Proper Proper/adjusted OK/filled OK/not OK OK/not OK OK/not OK Fitted/removed Proper/loose/Tightened proper/adjusted/not proper OK/not OK/Adjusted
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PRE-COMMISSIONING CHECK
Whenever you want to call a Service Engineer for commissioning, kindly ensure that - Installation work has been completed (i.e. exhaust pipe job has been completed with proper supports, if extended beyond the canopy) pipe line job is completed, if Fuel Tank is outside the canopy. Fuel Power cable laying, fitting and connection jobs are completed with proper glanding. If panel is out side canopy, Power Cable Control cable laying, fitting & connection jobs have been completed. important - Battery is charged. Most DG set is with AMF Panel, then 230 V AC supply is provided at the If the AMF Panel to check its operation and for Battery Charger. is available in the Diesel Tank. Diesel Engine is duly filled with Lube Oil. is available. Load Note: It is mandatory to get your Diesel Generating Sets commissioned on load and kindly do sign the commissioning report made by our Service Engineer.
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Fuel Level Check water from fuel Tank (Especially during winter Season.) Drain coolant Level. Check Water level in the Radiator Check for any leakage Check for any loose connections Check Battery condition Check Check Lube oil level and quality (lube oil should not be very thick with visible carbon and metal particles).
13
DONTS : DG set is with AMF panel please do not touch live wire as mains also flow If the from AMF panel even if DG SET IS OFF. check coolant level, while DG is running. Do not change any wiring or modify wiring it may attract void of Do not warranty do not get the DG set repaired and serviced by any unauthorized Please person. It may attract void of warranty. It should be done by the manufacturer or Kirloskar authorized Service Dealer.
Contd.
JAKSON & CO.
14
entry holes, if not in use, should be properly closed. Cable Unneccearly open the locked doors which can lead to damage Don't inside the lock. Exhaust pipe installation for Silent DG set should be very-very precise. The load of the Exhaust pipe should not come on the bellow and it should also not touch the roof body.
Note : Please note that normally DG sets are dispatched with dry batteries. So please make sure that batteries are properly charged by authorized dealer, as per the manufacturers recomendations, if batteries are not charged, as per the recommendations, life of the Battery is reduced drastically and it could be difficult for us to entertain warranty for that.
Silent DG and Genset with Radiator, Should be installed at a place where opening for hot air escape and intake of fresh air is available.
15
Cause
No fuel in tank. Air in fuel system. In sufficient speed of starter
Redress
Fill in fuel, vent fuel system. Vent fuel system. Charge batteries. Of above , or change lamp.
See above or the ready to start signal lamp does not light.
Defect of series resistor solenoid Consult authorised valve, or flame heater plug workshop. Paraffin precipitation of fuel Heat up fuel Pipings, change Filter Open cock Clean or change filter cartridge respectively. Fill in fuel , vent fuel system. inspect correct operation of fuel pump, replace if necessary, and check safe venting of tank. Clean fuel tank, fill in clean fuel replace filter, and vent fuel system. Inspect, replace if necessary or clean. Vent fuel system Change filter Reset start of fuel supply. Inspect and repair Set correct start of fuel supply.
Engine starts up but stops Fuel tank cock closed. after brief time Dirt in primary fuel cleaner or in fuel filter. No fuel in tank, no conveyance of fuel.
Interruption of air supply or heavy jamming of air filter. Air in fuel system Fuel filter jammed. Starts of fuel supply missed. Defect of exhaust brake.
16
Trouble
Cause
Engine is still cold.
Redress
Permit engine to heat up in operation Check start of fuel supply inspect injectors. Reset fuel injection system. consult workshop. Change air filter element.
Mis setting of fuel injection system. Engine emits black fumes. Engine is overloaded.
Fuel injection piping loose or Tighten fuel injection piping broken. or replace it, respectively. Heavy knocking of engine. Starts of fuel supply too early Set correct start of fuel supply. Mis-setting of valve air gaps Adjust & correct valve air gaps. Mechanical defects of engine Consult authorised workshop. Engine grows excessively hot. Slipping of V-Belts. V-belts broken. Defect of temperature governor. Defect of temperature Controller Lack of coolant. Radiator is dirty. Mis-setting of fuel supply. Tighten or Replace V-belts. Replace V-belts. Emergency operation; forced opening of valve plate. Perform electrical check of temperature controller. Fill in coolant. Clean radiator. Set correct engine in fuel supply Redress cause of trouble.
Consult workshop.
17
Trouble
Irregular speed of engine.
Cause
Defect of speed governor.
Redress
Inspect fuel injection pump and governor.
Mis-setting of fuel injection system Injection of excessively great fuel quantity engine emits black fumes Leakage of solenoid valve of cold starting device. Jammed air filter. Engine is worn. Defective exhaust brake.
Have fuel injection pump adjusted by specialised workshop. Replace solenoid valve.
Jammed paper filter cartridge. Replace paper filter cartridge. Deficient oil level. Pressure gauge or pressure gauge tube loose or defective. Leakage in oil system. Improper lube oil (viscosity). Defect of control valve for cooling of pistons. Heavy wears of bearings. Consult authorised workshop. Check and add oil. Inspect and replace or tighten. Check. Check brand of oil. Replace valve.
Defect of air filter system, and cooling of pistons, consult authorised workshop.
18
Trouble
Cause
Redress
Inspect rotor bearings, inspect oil supply to rotor.
No dirt deposits centrifugal Rotor jams. filter. Heavy blowing from venting hose of engine. No air supply from piston or compressor. Battery charging signal lamp alight while ignition is switched off. Battery charging signal lamp does not light up when ignition is switched on Defect of signal lamp. Excessively high oil level, damages of cylinder elements. Defect of cylinder element or of valve plate. Defective insulation in fanned cable
Adjust oil level, consult authorised workshop. Consult authorised workshop. Consult authorised workshop.
Interruption of D* governor and Plug in connector. generator Battery discharged Change battery. Replace V-belt. Inspect or consult workshop. Consult authorised workshop.
Battery charging signal lamp alight during normal operation Heavy boiling of battery.
Broken V-belt. Defective alternator. Defective governor, excessive contact resistance of negative polarity across brush holder and end shield bearing of generator.
Battery discharged.
Charge battery.
Starter terminal voltage too low. Check battery cells, recharge battery. Oxidized or loose terminal connections. Carbon brushes jam or are worn. Clean or replace brushes. Clean and fasten terminals.
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Cause
1) Insufficient residual voltage. 2) Improper connection 3) Low speed 4) Faulty Winding
Rectification
1) Excite the rotor using a battery. 2) Correct the connection 3) Reset the speed to the nominal. 4) Check the winding resistance and rewind if required.
5) Rotating rectifier failure 6) Faulty AVR Low no-load voltage 1) Low Speed 2) Faulty Rotating rectifier 3) Faulty Winding
5) Replace the rotating required. 6) Replace the AVR 1) Reset the speed to the nominal 2) Replace the rotating rectifier. 3) Check the winding resistance and rewind if required.
1) Set the rated speed of the prime mover. 2) Change AVR 3) Check the rotor winding resistance and if faulty, rewind it.
4) Over load on alternator High voltage on load 1) Capacitors on the load side 2) Faulty AVR setting or AVR is faulty Too high no-load voltage 1) Excessive speed 2) Correct the setting Replace AVR
JAKSON & CO.
4) Operate on specified load. 1) Disconnect the PF improvement capacitors 2) Correct the setting/Replace AVR 1) Adjust the revolving speed Correct the setting Replace AVR
20
Fault
Voltage oscillations
Cause
1) Incorrect AVR Setting specified limits 3) Insufficient engine flywheel
Rectification
1) Set the AVR stability pot
Unbalance Voltage
Quadrature droop Incorrect QDC-CT polarity reversed QDC-CT are not in W-phase
Interchange CT secondary Correctly by QDC Pot in AVR. Interchange CT secondary Check and rectify
21
Fault
Excessive overheating of alternator frame
Cause
1) Air flow (inlet-outlet) partially clogged or hot air is being circulated either from alternator or prime mover 2) Alternator operating at high Voltage at load 3) Alternator overloaded 4) Load PF less then 0.8 lag. Defective mounting or play inthe coupling
Rectification
1) Check air inlet - outlets of the alternator
2) Set the voltage to rated value 3) Operate at specified load 4) Correct the load power factor Replace the coupling & check the alignment Reset the speed to the nominal
Excessive Vibrations
Loose mounting Bolts Excessive vibration and 1) Three phase alternator 1) Check and correct the load humming noise coming is single phase loaded in from the alternator excess of acceptable limits 2) Start up with no-load:if 2) Rewind stator humming persists-faulty alternator stator winding Smokes, spark or Short circuit in the external Stop the gen-set immediately
flames coming from the circuit (including wiring alternator between alternator and control board)
Object fallen into the machine short circuit or flash in the stator winding
22
Fault
Alternator damaged by as significant impact which is followed by
Cause
Short circuit in external circuit faulty parallel connection (out of phase)
Rectification
Stop the gen-set immediately
humming and vibration Break or deterioration in the coupling Break or twist in shaft extension shifting or circuit of main field winding Bursting or unlocking of the fan Diode burnt, rectifier bridge damaged.
23
The engine cranks but will not fire. Check the fuel supply line. May be connection of fuel pipe at fuel tank is open.
24
the DC supply control MCBs F10 and F11 for 3 phase Supply. These Check should be in ON position. the battery voltage at terminal 1 and 2 in the AMF Panel. It should be at or Check above 24V/12V. all control wires at control terminals in AMF Panel. Check Battery terminals. They should be properly tightened and should not be Check corroded. LLOP signal at AMF Panel control terminal No. 8, up to 125 KVA It should Check be properly connected on engine terminal. is rattling should that the starter is engaged but it slips or cranks slowly. It there
The battery connection may be loose or corroded. Check and correct te problem. check if the battery voltage is at 24V/12V or above. If not get the battery charged before making further attempts as the battery is weak. If the main supply is available, set the battery charger to boost and wait till the battery voltage is as stated above.
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Check that the HRC fuses/MCB below the alternator contactor are O. K. Check that the setting at the Alt Voltage Monitor is not too high, set it to 360 V and try. Check the overload Relay if it is tripped and press the reset lever.
The Main supply is restored, but the load does not transfer.
Check the control MCBs at F4, F6. It should be in 'ON' position. Check if all three phases (RY, YB and BR) of Mains supply are available. These can be checked through selector switch and voltmeter provided on AMF Panel. All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay. If required, lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays. Increase the voltage setting gradually if Mains Voltage is not acceptable on load equipment.
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All Office Addresses, E-mail Addresses, Phone Nos. are on the Back Cover Page
JAKSON & CO.