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INSTALLATION
2.1 SELECTION OF SITE
Proper space should be there for placement and opening of doors of the Silent DG Set.
There should be at least 2 meter free space around the DG Set for proper access to initial
product delivery and installation, operation, service i.e. for general maintenance and
inspections and working space for major work such as overhauls or component
removal/replacement.
There should be cross ventilation and free flow of cool, clean and fresh air flow from
alternator end to engine to ensure proper cooling of DG Set. Exhaust gases and hot air
discharge should not re-circulate inside the acoustic enclosure (canopy).
For basement installations, supply of fresh air and forced ventilation through air ducts is
required to remove heat.
There should be no restriction for fresh air suction and hot air discharge. If 02 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.
A low height shelter for the Silent DG set should be avoided. It should not obstruct the
hot air outlet.
It is preferable to install the DG Set in an open area. No shade (roof) is required over it.
However, if the AMF Panel is outside the Acoustic Enclosure, then a shelter is
recommended for the Panel.
For Roof Top Installation, ensure that the civil structure is capable to 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.
The DG set should be located away from polluted surrounding such as corrosive fumes,
cement dust, fibres, cotton and toxic chemicals to avoid overheating of the DG set.
For Humid / Coastal atmospheric applications, anti condensations heaters are mandatory
for alternator.
A.
Note:
Please ensure that the foundation should not be made over any basement,
Water tank or Sewer line.
The radiated heat given off by the engine, generator and exhaust piping can result in a
temperature high enough to adversely effect operating and maintenance personal or the
performance of the genset. Locate the genset in a room or area that will provide or allow
sufficient ventilation to remove this heat as well as the heat radiated from the engine
cooling water by the radiator.
If the enclosures are placed in an enclosed place, ensure that enclosure is well ventilated
and exhaust gases are driven out of the enclosure.
Unit
mm
15 KVA - 35 KVA
63
76
75 KVA
100
Exhaust pipe
Unit
mm
15 KVA - 35
40 KVA - 62.5
KVA
KVA
63
75 KVA
100 KVA-125
KVA
76
100
125
Dia
SL Series
Description
Unit
mm
K Series
Description
Unit
mm
275 KVA
125
320KVA
150
400KVA-625 KVA
2 x 150
The fuel system must be capable of delivering to the engine a clean and continuous supply of
fuel. When designing a fuel system, always incorporate the requirements of Local, State, or
National Codes, which may pertain to either the fuel system or the electrical apparatus utilized
by the system.
Bulk fuel storage is the most preferable method of providing fuel supply. This method allows
bulk fuel purchases which will minimize dirt and contamination possibilities, especially when the
fuel is seldom used. The bulk storage tank may be located either above or below the ground. A
vent must be installed on the main tank to relieve the air pressure created by filling the tank as
well as preventing a vacuum within tank as fuel is consumed. The tank bottom should be
rounded and placed on a 2 degree tilt to assure a concentrated settling of both water and
sediments. At the low point of the tank a drain valve should be installed to remove water that
may accumulate due to condensation.
Underground tanks must be pumped periodically to remove this water. This is best done by
placing a tube through the filter pipe to the low end of the tank. For these reasons it is
imperative that the tank be placed in or on stable ground to assure that eventual settling does
not change the location of the low point of the tank. Burying the tank below the frost line will
help in avoiding seasonal settling. Another consideration to be made when locating the main
tank is the height difference between it and the auxiliary tank (day tank). The maximum vertical
lift capability of a standard electric motor driven fuel transfer pump is 5m. Do not place either
tank at a level that would exceed the pump lift capabilities. Also keep in mind the possibilities of
pressure drop created by excessive horizontal distances and pipe work bends. The fuel delivery
line carrying fuel to the engine and the fuel return line for carrying excessive fuel back to the
tank should be no smaller than the fitting sizes on the engine. For longer runs or extremely low
ambient temperatures increase the size of these lines to ensure adequate flow. The fuel lines
can .be made of any fuel compatible material such as steel pipe or fuel line tube that will
tolerate ambient conditions. Overflow piping should be of the same material and one size larger.
The fuel return line should enter the tank at the top and contain no shut-off valve. This line
should be designed with a minimum amount of bends or dips to prevent an air lock in the
system. The fuel delivery line should pick up the fuel from the point no lower than 20mm from
the bottom of the tank. If at all possible locate this line at the end of the tank opposite that of
the return line and at the high end of the tank. Flexible fuel lines should be used at a point
between the tank and engine (preferably adjacent to the genset) to avoid the potential damage
that could be created by vibration.
B.
Day Tanks
Auxiliary tanks or day tanks as they are commonly referred to are recommended. All standard
gensets with acoustic enclosure are provided with tank fitted in the base frame. This day tank
will produce a ready fuel supply.
Reduce friction
Cool
Seal
Scavenge
Dampen shocks
The operating life of an engine depends on the use of the correct type of lub. oils. To ensure
this, oils recommended by the engine manufacturer should be used. Oil confirming to IS: 496(
1979 HD type 5 or U.S. Military standard MIL-L-2104-C must be used for industrial/ automotive
naturally aspirated and turbo charged diesel engines.All standard lubricating oils have a brand
name and the SAE number. The brand name indicates the oil specification. The SAE number
denotes the oil viscosity. Oil viscosity is selected according to the ambient temperature as
shown below:
Temperatures
above 45 C
SAE 40
Temperatures
10 C to
45 C
SAE 30
Temperatures
-5 C to
10 C
SAE 20 W
Temperatures
-15 C to
-5 C
SAE 10 W
Where the temperature variation between minimum and maximum is very wide, multigrade oils
should be used. Also multi-grade oil is better than mono-grade oil.
Example : SAE 20W40 is a multi-grade oil and can be used where atmospheric temperature is
between -5 C to 45 C and above. (Which is applicable to normal Indian climatic condition.)
The oil sump is usually fitted on the lowest part of the engine. It is provided with a drain plug to
Enable oil draining. Oil sumps are of two types: Standard Sump - for stationary applications.
Deep sump - for industrial automotive applications.
LUBRICATING SYSTEM
The dipstick measures the quantity of oil in the sump. It is usually grooved with low and high
markings to help users maintain the correct oil level in the sump.
DIPSTICK
NOTE:
A. correct size Cable glands should always be used for holding the cable.
B. Control Wiring should always be done with 2.5sq.mm copper cable.
If dry battery is supplied along with the DG set then initial charging of the battery is
required.
Please get initial charging of the battery done from an authorized service dealer of the
battery manufacturer.
The initial charging process is of 72 hours.
Specify gravity of acid inside the battery should be 1.23 to 1.28 kg/liter.
If charged battery has been provided along with the DG set, and the DG set is not in use
then ensure that at positive terminal battery lead is not connected. It should be
connected at the time of the commissioning of the DG set.
Charged battery may be used for commissioning of DG set within 15-20 days; else recharging of charged battery is required.
Always connect the battery with the proper battery charger. The battery should be
connected to the battery charger, which is connected with 230V AC supply.
The Battery charger is provided with an AMF Panel (Auto Mains Failure Panel) under the
standard scope of supply. 230V AC supply is essential for battery charger operation.
Note: