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HGI Generators HRD270T1, Operation And Maintenance Manual

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Ravenstor Road
Wirksworth
Derbyshire 
DE4 4FY
ENGLAND

Sales Tel:

     

+44 (0) 1629 824 284

Sales Fax:     +44 (0) 1629 824 613
Email:         [email protected]
 [email protected]
Website:      www.hgigenerators.com

Operation and Maintenance Manual

27kVA 3 Phase Diesel Generator

Build No: HRD270T1, H

Publication   498-1052       

© Harrington Generators International Limited 
All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in 
any medium by electronic means or other) without the written permission of the copyright holder except in accordance with 
the provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to 
Harrington Generators International Limited at the address above. 

Any reference to trademarked product names used within this publication is owned by their respective companies.

Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.

Summary of Contents for HRD270T1

Page 1: ...cluding photography or storing in any medium by electronic means or other without the written permission of the copyright holder except in accordance with the provisions of the Copyright Designs and Patents Act 1988 Applications for the copyright holder s written permission to reproduce any part of this publication should be addressed to Harrington Generators International Limited at the address a...

Page 2: ...ly 14 A MC Updated and released following review Mar 16 B MC Updated for Coolant Notice revised battery isolator and addition of fuel priming switch DofC notice Installation notes Wiring Diagrams Jan 17 C MC General Update Warranty Iss H Wiring Sept 17 D MC Warranty Iss I Declarations of Conformance Updates ...

Page 3: ... General Arrangement HRD270T1 6 270T1 8 SAFETY 10 A few words about safety 10 Operator Responsibility 10 Precautions 10 Electrical Safety 19 Lifting and Moving 19 Hazards to Health 20 OPERATION 22 Generator Layout 22 Output Panel 23 Control Panel 23 Emergency Stop 26 Terminal Output Pod 26 Battery Isolator 27 Installations 27 Pre Operation Checks 27 Starting 30 Stopping 30 ...

Page 4: ...lectrical Output 33 MAINTENANCE 34 Maintenance Schedule 34 Safety Precautions 35 Maintenance Routine 35 PARTS AND SERVICE 40 Contact Details 40 Warranty Statement 40 Functional Spares 41 TRANSPORTATION AND STORAGE 42 WIRING 43 HRD270T1 43 HRD270T1 44 MANUFACTURER S SERVICE AND USER GUIDES LINKS 45 Kohler Operators and Maintenance Manual 45 Deep Sea 4510 User Guide 45 Mecc Alte ECO ECP User Manual ...

Page 5: ...HRD270T1 1500 RPM Diesel Generator for illustration only ...

Page 6: ...nient document holder located on the inside of the service side door to store the manual and other documents in Make sure that the manual is available to all users throughout the generator s life span If in doubt about the functionality of any of the equipment within this document please contact HGI or seek other expert advice Every effort has been made to ensure that the information given in this...

Page 7: ...procating internal combustion engines EN60204 1 Safety of machinery Electrical equipment of machines General requirements EN12601 Reciprocating internal combustion engine driven generating sets Safety BS EN 61000 6 1 EMC Generic standards Immunity for residential commercial and light industrial environments BS EN 61000 6 2 EMC Generic standards Immunity for industrial environments BS EN 61000 6 3 ...

Page 8: ...ld Code This is a code number which tells us the exact build standard to which the generator was built This is important when ordering spares or contacting our Technical Help Line Serial No This is a unique number which identifies the generator This is important when ordering spares or contacting our Technical Help Line Year of Manufacture Year of Manufacture e g 2013 Electrical Power This is the ...

Page 9: ...nk empty Approx 902 kgs Approx 945 kgs Weight fuel tank full Approx 1026 kgs Approx 1075 kgs Fuel Commercial diesel with up to 10 bio diesel i e B10 blend Output Output Type Multi Voltage Switched Frequency 50 Hz Voltages 110 230 400V Starting System Electric Start via Control Module as local or remote start Output Configuration Sockets and Terminal Output Socket Arrangement 400V 1 x 32A 3P N E IP...

Page 10: ...un Time at 50 load app 44 hrs Consumption at 50 load 3 4 l hr Canopy Canopy Type Canopied set with integral bunded fuel tank Material Base Structural Steel Canopy Smooth galvanised steel Finish Base Iron phosphate pre treatment zinc rich primer then architectural grade powder coating Canopy Iron phosphate pre treatment then architectural grade powder coating Colour Base RAL9005 Jet Black Semi Glos...

Page 11: ... 1 2 LMED0048967900 S Connector Kit for Lombardini KDI 1 3 020 658 DER Mecc Alte ECP28 VL 4 Alternator 1 4 040 779 028 T500X Alternator X member 1 5 040 779 A T500X Canopy 1 6 070 470 AV Mount Captive M10 50 shore 2 7 160 136 A T500X Foam Kit 1 8 160 136 B T500X Additonal Foam Kit Lombardini 1 9 610 528 T500X KDI2504M Engine Install Kit 1 10 620 509 T500X Exhaust Kit Lombardini 1 11 630 504 T500X ...

Page 12: ... Bolt down Holes for M16 Fixings Fully Bunded Base containing 150L Fuel Tank Cable Outlet for Terminal Output Earth Cable Remote Wiring Bolt on End Panel with access to Silencer Lockable Door with access to Battery Isolator Main Door Stay External Fuel Connections Forklift Pods Lockable Main Service Door with access to Fuel Filler Neck Document Holder Internal External Fuel Selector Output Sockets...

Page 13: ...mber 040 779 029 1 3 Alternator Adaptor Plate 040 779 041 1 4 Canopy Kit 040 779 A 1 5 AV Mount 070 470 2 6 Foam Kit 160 136 A 1 7 Additional Foam Kit 160 136 B 1 8 Engine Install Kit 610 528 1 9 Exhaust Kit 620 509 1 10 Battery Kit 630 504 1 11 Fuel Kit 640 511 LOM 1 12 Hardware Kit 660 504 1 13 Control Panel Kit 1ph 3ph Switched 690 563 1 14 Connector Kit for KDI2504M LMED0048967900 S 1 15 DC En...

Page 14: ...y Exhaust Outlet Radiator Access Lifting Beam Access Terminal Earth Remote Cable Outlet Bolt on Panel for Battery Removal Key Padlock Lockable Hinged Service Door with access to Internal Fuel Filler Fuel Selector Valve Cool Air Inlet Tow Bar Bolt Down Holes External Fuel Connections Oil Drain Bolt on Panel for Silencer Access Hot Air Outlet Hot Air Outlet Door Stay Key Padlock Lockable Hinged Serv...

Page 15: ...n result in product damage or to draw attention to additional information or explanations Operator Responsibility Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output sockets and connections Be sure that anyone who operates the generator receives proper instruction If you have any doubts about the safe operation of this equipment please co...

Page 16: ...is generator must only be filled with commercial diesel fuel containing up to 10 bio fuel If special grades of diesel e g 100 Bio Diesel are to be used consult HGI first to discuss its suitability Pt No 499 945 004 Qty 2 Next to Inlet Outlet Vents INLET AND OUTLET VENTS TO BE KEPT CLEAR These must be kept free from obstructions to allow a free flow of cooling air or the engine and alternator could...

Page 17: ...ct our Technical Help Line Pt No 499 945 011 On side panel CHECK ENGINE OIL LEVEL DAILY Check the oil level each day and top up if necessary to the top mark given in the oil level diagram above If oil consumption is excessive investigate further Pt No 499 945 011 On side panel LOW LOAD RUNNING Operating the generator at low load levels for extended periods can result in high levels of carbon build...

Page 18: ... side panel STOP ENGINE AND ALLOW TO COOL DOWN FOR A FEW MINUTES BEFORE REFUELLING In addition DO NOT SMOKE while refuelling use a funnel or similar to prevent fuel spillage avoid over filling the fuel tank and wipe up any spilt fuel Avoid contact of fuel with skin Pt No 499 945 011 On side panel DO NOT SPILL FUEL ONTO HOT SURFACES The exhaust outlet and the area around it in particular are hot Pt...

Page 19: ...ED THE GENERATOR S BRASS EARTH STUD SHOULD BE CONNECT ED TO AN EXTERNAL EARTH THIS EXTERNAL EARTH CAN BE AN EARTH SPIKE OR ANY SUITABLE EARTH POINT THE RCD SHOULD BE TESTED DAILY BY PRESSING THE TEST BUT TON AND CHECKING IT DOES TRIP If the generator is to be used for a fixed installation or installed on the same site for a long period it should be installed by a competent person The User should b...

Page 20: ... opened whilst the generator is running Pt No 499 945 020 Qty 1 Below Snap Connectors EXTERNAL FUEL SUPPLY Information label showing the positions of the snap connectors when using an ex ternal fuel supply Label also advises that Diesel Only should be used Pt No 499 945 022 Qty 1 On Control Panel Dual Voltage Generators 400V OUTPUT Advisory label showing voltage of the generator Pt No 499 945 023 ...

Page 21: ...isposal practices Pt No 499 945 049 Qty 1 On lifting Beam Service Access Side HOT WATER UNDER PRESSURE CHECK COOLANT LEVEL DAILY Coolant level must be sufficient to appear in the filler neck DO NOT OPEN A HOT RADIATOR Pt No 499 945 035 Qty 1 On lifting Beam Expansion Bottle Side EXPANSION BOTTLE Coolant level should reach the bottom of the radiator filler neck and should be between the level marks...

Page 22: ...aken not to come into contact with the terminals Pt No 499 945 043 Qty 1 On the Terminal Box Cover top right close to Sockets ELECTRICITY IS DANGEROUS Warning about the danger or using Elec trical equipment and the difference in phases Pt No 499 945 044 Qty 1 On High Mark Level of Expansion Bottle if not embossed on bottle HIGH LEVEL Informational to denote the High Level mark on the expansion bot...

Page 23: ...ive off small quantities of hydrogen gas Do not smoke or use naked flames while working on a battery NEVER attempt to burn a battery as a method of disposal On front panel over battery compartment Part of label No 499 945 006 DISCONNECT NEGATIVE LEAD FIRST AND RECONNECT LAST This is to ensure that if a spanner slips you cannot create a circuit from the live battery post to the generator chassis On...

Page 24: ...pment Regulations 1998 LOLER SI 1998 No 2307 and the following publication should be observed HSE ACoP publication L113 Safe Use of Lifting Equipment Lifting Operations and Lifting Equipment Regulations As a guide line only you should ensure that all lifting equipment is Sufficiently strong stable and suitable for the proposed use The load and anything attached must be suitable to be lifted Positi...

Page 25: ...material enters the eye flush with copious quantities of clean water If persistent irritation occurs obtain medical attention Ingestion In the unlikely event that ingestion occurs wash out the mouth with water and seek medical attention Do not induce vomiting Diesel Fuel May cause skin irritation Gloves overalls and eye protection should be worn when handling this product As for engine oil above F...

Page 26: ...duce vomiting Exhaust Fumes Exhaust fumes are very hot and con tain carbon monoxide which can cause unconsciousness and death in humans and animals It is odourless and tasteless but diesel exhaust fumes contain other chemicals and soot which will irritate the eyes and breathing and will usually alert the user to the presence of fumes Symptoms of carbon monoxide poisoning are dizziness nausea fatig...

Page 27: ... can stop and start the set and monitor the generator and engine condition at the set using the green start and red stop buttons and instrument panel on the DSE4510 control module When configured for remote start the output terminal pod on the output panel is used to connect the set to a remote Automatic Mains Failure AMF panel or timer volt free switch The switched connection can then transmit a ...

Page 28: ...ol Module Protection MCB 3 Output Protection Panel 4 DSE4510 Control Module 5 Phase Selection Switch 6 DC Isolation Switch 7 USB Controller Program Socket Output Protection Panel Single Phase Three Phase 1 2 3 4 5 Item Description 1 Single Phase RCD 30mA 2 RCD Test Buttons 3 110 230V 63A 2 Pole MCB 4 Three Phase RCD 100mA 5 400V Socket and Terminal Output 4 Pole MCB The RCDs should be tested by pr...

Page 29: ...e will go into standby when no com mon alarms have been triggered after 1 minute of inactivity When the emergency stop is pressed in the DSE module will not go into standby and will drain the battery Instrumentation To access various instrumentation displays you will need to press the up down buttons on the engine control module Each page of instrumentation can be accessed sequentially in this ord...

Page 30: ...VOLTAGE The generator output voltage has fallen below the pre set pre alarm setting after the Safety On timer has expired GENERATOR OVER FREQUENCY The generator output frequency has risen above the pre set pre alarm setting GENERATOR UNDER FREQUENCY The generator output frequency has fallen below the pre set pre alarm setting after the Safety On timer has expired INTERNAL MEMORY ERROR Either the c...

Page 31: ...5 Earth Stud If the set has been configure to provide terminal output supply and or remote control the electrical connections from the generator will have been made and tested during installation All cables connecting to external panels and output will have been passed through the cable gland opening Three Phase Terminal Connections Ensure that the connections are secure and correctly sequenced Pl...

Page 32: ...alified personnel in accordance with appropriate regulations e g Electricity Safety Quality and Continuity Regulations 2002 S I 2002 2665 and Electrical Safety regulations cited previously in this document Pre Operation Checks Before carrying out the following checks ensure that the control module is switched off and or the battery is isolator is switched off Engine Oil Check the oil level BEFORE ...

Page 33: ...ICE DO NOT use the expansion bottle as indicator of coolant level NOTICE COOLANTS Organic Acid technology OAT Hybrid organic acid technology HOAT and G5 antifreeze coolants offer exceptionally long service life compared to glycol antifreeze It is recommend that OAT HOAT and G5 coolants are not mixed with each other or any other type of coolant Where possible always use the same type as that suppli...

Page 34: ...e internal tank is being used then the fuel level can be checked using the sight level in the base of the generator If the engine is running the fuel level can be checked at the DSE4510 control module If the fuel is low the Low Fuel Alarm indicator will be lit and the generator will shutdown to prevent air locking in the fuel system This functionality is only available when using the internal tank...

Page 35: ...load wherever possible Also see Maintenance Section Stopping 1 Switch off the electrical output and disconnect the load from the generator s output sockets 2 Allow the generator to run off load for 2 minutes to cool down 3 Press the red stop reset button on the DSE4510 moudle or if being operated remotely the Stop signal will be transmitted to the DSE4510 4 The engine will then stop after the shut...

Page 36: ...he engine over and the oil pressure icon is displayed on the Engine module The control module believes that oil pressure is present when the engine is off Check the oil pressure switch has not gone faulty Check the control module has not gone faulty by swapping it Check fuel level in the tank s and that the fuel selector switch is set to the correct tank i e internal or external Engine turns over ...

Page 37: ...e Speed Fault If the engine does not run at 2400 to 3420 rpm it will close down The most common cause of incorrect speed is air or contamination in the fuel system Bleed the system and try starting again Other Engine Faults Symptom Cause and Remedy Has the miniature circuit breaker MCB tripped or pop out breaker tripped Before resetting disconnect all equipment plugged into the sockets Look for an...

Page 38: ...d use the MCB on the generator to turn the supply ON to the suspect equipment If a piece of equipment trips the earth leakage unit repeatedly make sure it cannot be used on another supply by removing the plug and labelling Faulty Unsafe Check the miniature circuit breaker MCB Each 110V 230V output socket has its own MCB to prevent excessive electrical load being taken through that socket Check if ...

Page 39: ... electrical system Use a damp cloth or similar CLEANING AND CHECKING OPERATION DESCRIPTION PERIODICITY HOURS 10 200 500 1000 1500 5000 Engine Oil Level º º º º º º Coolant Level º º º º º º General Inspection Leaks and Oil º º º º º º MCB RCD Test º º º º º º Dry Type Air Filter º º º º º Radiator heat exchange surface and intercooler º º º º º Alternator Belt Tension º º º º Rubber Hoses º º º º ...

Page 40: ...ty environments Check and Replace Engine Oil NOTICE The engine oil must be high performance semi synthetic as specified by the engine manufacturer in order to achieve the 500hr oil change Lower performance oil will require more frequent oil changes Refer to Pre Operational Checks to check the engine oil level and replenish Replace the engine oil every 500 hours operation When changing the oil or t...

Page 41: ...e or leaks Check the cap and seal for signs of damage Clean the radiator matrix of leaves or similar debris Check the coolant level when the engine is stationary and on a level surface The radiator should be filled to typically 1 cm above the core of the radiators matrix Replace coolant every 12 months or as specified by the engine manufacturer s guidelines Refer to Engine Manufacturer s Operation...

Page 42: ...th the engine manufacturers instructions Exhaust System Inspect the exhaust system and silencer at the flexible sections and joints in particular Check the exhaust is adequately supported and secured Check for leaks and signs of burning of the insulation Replace insulation if necessary If the engine has run on low load for a considerable period the exhaust may be sooted up Run the engine on low lo...

Page 43: ...t earth pins and the generator frame Run on then full load Operating the generator at low load levels for extended periods can result in high levels of carbon build up in the engine and exhaust system which can lead to excessive smoking reduced efficiency and overheating Looking at the silencer s outlet will give some indication this has happened After each service the generator should be run firs...

Page 44: ...iator clean 3 Replace Air Filter 4 Check Coolant Hoses Yes No Yes No Yes No Yes No 200 Hourly Checks 1 Complete 10 hourly checks 2 Check Clean the air filter 3 Check Radiator surface Yes No Yes No Yes No 1500 Hourly Checks 1 Complete 1000 hourly checks 2 Check Fuel Hoses 3 Yes No Yes No Yes No 500 Hourly Checks 1 Complete 200 hourly checks 2 Complete 200 hrs service 3 Check alternator Belt Tension...

Page 45: ... Website www hgiparts com Service Department Tel 44 0 1629 821 647 Email service hgigenerators com Technical Help Line Staffed by friendly Technical Engineers who will advise on the correct generator for your power requirements its application and safe use Tel 44 0 1629 821 614 or 821 652 Warranty Statement See HGI Website for latest warranty statement https www hgigenerators com warranty statemen...

Page 46: ...52 Generator Parts DSE4510 Controller 125 238 3 Phase RCD 110 548 3 Phase 25A 1 Pole MCB 110 325 1 Phase RCD 110 504 1 Phase 63A 3 Pole MCB 110 163 110 230V 16A Socket MCB 15A 110 015 110 230V 32A Socket MCB 30A 110 030 Door Safet Switch 080 964 Fuse 2A 100 002 Fuse 5A 100 005 Relay Module 140 560 Automobile Fuse 15A 100 212 Automobile Fuse 20A 100 213 Automobile Fuse 35A 100 304 Alternator HRD270...

Page 47: ... petroleum jelly Long Term over 6 months For long term storage each engine manufacturer will have their own recommendations typically 1 Replace engine oil with a special inhibiting oil 2 Flush through fuel system and leave full with a special inhibiting compound 3 Spray connectors in the loom and plug in sensors with Vaporol Inhibitor or similar Please contact HGI for further details Alternator No...

Page 48: ...Harrington Generators International 43 HRD Diesel Generator 498 1052 Wiring ...

Page 49: ...Harrington Generators International 44 HRD Diesel Generator 498 1052 Wiring ...

Page 50: ...e at the time of publication If in doubt about the recency of the documents then please contact the manufacturer or visit their website for the latest information Kohler Operators and Maintenance Manual http www kubota co uk after sales support publication Deep Sea 4510 User Guide http www deepseaplc com products dse genset Mecc Alte ECO ECP User Manual http www meccalte com If you are still unsur...

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