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User manual 

Under

 

normal

 

conditions,

 

the

 

air

 

volume

 

generated

 

from

 

the

 

radiator’s

 

fan

 

is

 

enough

 

to

 

meet

 

the

 

requirement

 

of

 

the

 

working

 

room

 

ventilation.

   

The

 

air

 

inlet

 

temperature

 

of

 

the

 

engine

 

shall

 

be

 

below

 

30

 

degree

 

Celsius.

 

If

 

the

 

air

 

inlet

 

temperature

 

keep

 

rising

 

above

 

30

 

degree

 

Celsius,

 

the

 

engine’s

 

output

 

power

 

will

 

be

 

reduced,

 

and

 

therefore

 

fresh

 

air

 

from

 

outside

 

shall

 

be

 

introduced

 

into

 

the

 

generator

 

set’s

 

working

 

room

 

in

 

a

 

timely

 

manner.

 

If

 

the

 

generator

 

set

 

is

 

furnished

 

with

 

a

 

remote

 

radiator,

 

forced

 

air

 

circulation

 

for

 

the

 

generator

 

set

 

working

 

room

 

is

 

a

 

must.

 

The

 

forced

 

air

 

circulation

 

need

 

two

 

fans,

 

one

 

fan

 

is

 

responsible

 

for

 

air

 

intake,

 

another

 

is

 

air

 

exhaust,

 

which

 

exhausts

 

hot

 

air

 

to

 

outside.

 

When

 

the

 

engine

 

is

 

furnished

 

with

 

propelled

 

fan,

 

it

 

is

 

recommended

 

that

 

a

 

separate

 

pipe

 

is

 

needed

 

to

 

exhaust

 

the

 

gas

 

which

 

generated

 

from

 

the

 

crankcase

 

to

 

outside.

 

Otherwise

 

the

 

exhaust

 

gas

 

from

 

the

 

crankcase

 

will

 

accumulate

 

on

 

the

 

radiator,

 

which

 

will

 

cause

 

the

 

radiator

 

stuck

 

by

 

dirty

 

material,

 

and

 

as

 

a

 

result,

 

the

 

heat

sinking

 

capacity

 

will

 

be

 

reduced.

 

2.5.3

 

Exhaust

 

Our

 

standard

 

configuration

 

diesel

 

generator

 

sets

 

provide

 

accessories

 

such

 

as

 

industry

 

heavy

 

silencer,

 

soft

 

corrugated

 

pipe

 

and

 

elbow

 

etc.

 

Users

 

can

 

design

 

the

 

exhaust

 

system

 

of

 

generator

 

set

 

working

 

room

 

by

 

themselves.

 

When

 

design

 

and

 

install

 

the

 

exhaust

 

system,

 

please

 

consider

 

the

 

following

 

aspects:

 

Ensure

 

the

 

total

 

exhaust

 

backpressure

 

no

 

higher

 

than

 

the

 

maximum

 

allowed

 

value

 

specified

 

by

 

the

 

engine(usually

 

generator

 

set’s

 

maximum

 

exhaust

 

backpressure

 

is

 

no

 

more

 

than

 

5Kpa)

 

Fix

 

the

 

exhaust

 

system

 

to

 

make

 

sure

 

the

 

exhaust

 

manifold

 

and

 

turbo

charger

 

are

 

not

 

subject

 

to

 

the

 

vertical

 

pressure

 

and

 

side

 

stress.

 

Reserve

 

some

 

space

 

for

 

hot

 

shrinkage

 

and

 

cold

 

expansion.

 

Reserve

 

space

 

for

 

generator

 

set

 

vibration.

 

Reduce

 

exhaust

 

noise

 

level.

 

Overload

 

of

 

exhaust

 

backpressure

 

will

 

cause

 

following

 

adverse

 

effect:

 

Output

 

power

 

loss

 

Fuel

 

efficiency

 

reduce

 

Exhaust

 

gas

 

temperature

 

rise

 

Note:

 

When

 

more

 

than

 

one

 

generator

 

set

 

are

 

installed,

 

try

 

not

 

to

 

discharge

 

all

 

of

 

the

 

generator

 

sets’

 

gas

 

from

 

one

 

exhaust

 

path.

 

If

 

no

 

separated

 

exhaust

 

pipe

 

is

 

allowed,

 

under

 

the

 

condition

 

that

 

the

 

total

 

backpressure

 

will

 

not

 

exceed

 

the

 

generator

 

sets’

 

total

 

backpressure

 

a

 

moveable

 

separate

 

panel

 

shall

 

be

 

installed

 

inside

 

of

 

the

 

branch

 

exhaust

 

pipe

 

so

 

that

 

to

 

prevent

 

the

 

gas

 

from

 

return.

 

In

 

the

 

exhaust

 

system,

 

soft

 

corrugated

 

pipe

 

shall

 

be

 

used

 

to

 

connect

 

the

 

exhaust

 

pipe

 

with

 

the

 

turbocharger,

 

this

 

pipe

 

has

 

three

 

functions

 

as

 

follows:

 

Separate

 

the

 

diesel

 

engine

 

with

 

vibration

 

and

 

the

 

weight

 

of

 

exhaust

 

pipe.

 

Compensate

 

the

 

heat

 

expansion

 

of

 

exhaust

 

pipe.

 

If

 

the

 

diesel

 

generator

 

set

 

is

 

installed

 

on

 

the

 

anti

vibration

 

base

 

frame,

 

the

 

corrugated

 

pipe

 

can

 

compensate

 

sideway

 

movement

 

when

 

engine

 

start

 

or

 

stop.

 

Note:

 

1. Serious

 

damage

 

will

 

occur

 

when

 

rain

 

or

 

condensed

water

 

enter

 

into

 

engine’s

 

exhaust

 

system.

 

Therefore,

 

one

 

water

 

discharge

 

opening

 

shall

 

be

 

installed

 

in

 

the

 

long

 

exhaust

 

pipe,

 

the

 

position

 

of

 

which

 

shall

 

be

 

close

 

to

 

the

 

generator

 

set.

   

2. When

 

the

 

top

 

of

 

the

 

exhaust

 

pipe

 

is

 

above

 

the

architecture,

 

lightening

 

protection

 

is

 

needed

 

(connect

 

to

 

the

 

ground)

 

2.5.4

 

Noise

 

reduction

 

When

 

diesel

 

generator

 

set

 

is

 

running,

 

normally

 

it

 

will

 

generate

 

noise

 

level

 

of

 

90

110dB,

 

and

 

the

 

more

 

the

 

load,

 

the

 

higher

 

the

 

noise

 

level.

   

In

 

order

 

to

 

meet

 

the

 

noise

 

level

 

standards

 

established

 

by

 

the

 

local

 

environmental

 

protection

 

bureau

 

and

 

to

 

prevent

 

the

 

noise

 

pollution

 

caused

 

to

 

ambient

 

environment,

 

which

 

will

 

affect

 

people’s

 

normal

 

life,

 

to

 

reduce

 

noise

 

level

 

of

 

diesel

 

generator

 

set

 

is

 

also

 

Summary of Contents for DHY34KSE

Page 1: ... REGULATION STARTING METHOD DISPLACEMENT cc OIL CAPACITY L ALTERNATOR RATED POWER kW kVA POWER FACTOR Cosφ VOLTAGE REGULATION LOW OIL PRESSURE BLOCK ON START UP LOW BATTERY HIGH TEMPERATURE ON WATER LOW OIL LEVEL LOW RUNNING ON ENGINE EMERGENCY STOP N G kg G W kg PRODUCT DIMENSIONS mm CAPACITY units container 25 31 28 34 50 230 400 45 IL NT MRS 10 INCLUDED 1x12v 60Ah 93 10 5 2 9 3 18 10 68 HY4102 ...

Page 2: ...DIESEL GENERATOR Models Hyundai Engine Series Operation and Maintenance manual ...

Page 3: ...tock and property Some or all of the following PPE warning signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so may result in personal injury Warning Signs and Symbols FOLLOW safety messages to avoid or reduce risk of injury or death DANGER indicates a hazard which if not avoided could result in serious injury or death WARNING indicates a haza...

Page 4: ...e even if doors and windows are open If you think you or someone around you has been affected by carbon monoxide poisoning Leave the affected area and get fresh air immediately Open doors and windows and turn the machine off See your doctor immediately or go to hospital let them know that you suspect carbon monoxide poisoning DO NOT use in an enclosed area or a moving vehicle General fuel safety C...

Page 5: ...rior to carrying out any maintenance work Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage you should stop using the equipment The damaged item must repaired by an electrically compe...

Page 6: ... starting DO NOT pour water directly over the generator nor wash it with water For each use make sure that the generator has been electrically grounded earthed Failure to do so can be fatal DO NOT smoke while charging a battery The battery emits flammable hydrogen gas which can explode if exposed to electric arcing or open flame Keep the area well ventilated and keep open flames sparks away when c...

Page 7: ...is close to the battery and fuel because the mixture of volatilization from fuel and hydrogen generated by battery charging process will cause explosion when it meets sparkle or naked flame The generator set installation room shall be facilitated with BC and ABC fire extinguisher and operators shall be familiar with the knowledge on how to use it When fan protection cover or other protection cover...

Page 8: ...t is running do not attempt to reach under or around the guards to do maintenance or for any other reason Keep hands arms long hair loose clothing and jewelers away from pulleys belts and other moving parts SAFEGUARD WARNING Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105 dB A Prolonged exposure to noise levels above 85 dB A is haza...

Page 9: ...nal disconnected prior to attempting to connect or disconnect load connections Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground Make sure connect generator set to earth Replace the generating set terminal box cover as soon as connection or disconnection of the load cables is complete Do not operate the generating set without the cover secur...

Page 10: ...erator Set Working Room 4 2 5 Installation of Generator Set 5 2 6 Cooling system 7 2 7 Lubricant system 8 2 8 Fuel system 8 2 9 Battery 10 2 10 Electrical Connection 11 2 11 Power distribution system 11 3 Operation 3 1 Inspect Before Operation 12 3 2 Generator set s running 12 3 3 After Running 13 3 4 Record for running 13 3 5 Matters need attention 13 3 6 Operation for control system 14 3 7 ATS c...

Page 11: ...tandby power supply to provide continue electric power for non invariable loads The generator set is suitable for the area where must ensure continue power supply such as hospitals industrial facilities airports etc Keep the generator set standby state at any time and start to run when the mains supply is abnormal Emergency service Used as auxiliary power supply to solve energy interruptions that ...

Page 12: ...a pusher fan and thermostat The alternator has its own internal fan to cool the alternator components 1 6 Electrical System The engine electrical system is 12 volt or 24 volts DC negative ground earth This system includes an electric engine starter a battery and a battery charging alternator For DC 12 volts electrical system one battery is given For 24 volt system two lead acid batteries are given...

Page 13: ...ilitated onnect direc valve is an UNDAI Pow n for the rplus lubrica t by openin ransportatio been designe Standard ca fting hole o enerator set canopy roo me which b o have stati the generato Optional S ed with heat l the pre hea n be started gency cases 3 y with ctly to nother wer It users ant or g the on ed for anopy on the ts we of and better ionary or set Spare ter for ater is under s and al d...

Page 14: ...nect to other architecture s foundation The width and depth of foundation shall meet requirement Ensure foundation s levelness and smoothness If possible waste discharge sink can be sued so that the waste oil can be discharged in a timely manner Cable channel for generator power output cable need to be reserved Normally concrete foundation is reliable simple and preferable When pouring the concret...

Page 15: ...set to outside For example corrugated vibration reduction pipe has been used to connect exhaust pipes air exhaust path fuel inlet pipe fuel return pipe and busbar cable etc all of these parts need to use soft connections Only in this way we can reduce the adverse effect caused by the vibration of generator set to the minimum extent 2 5 2 Ventilation When a generator set with a complete set of radi...

Page 16: ...essure and side stress Reserve some space for hot shrinkage and cold expansion Reserve space for generator set vibration Reduce exhaust noise level Overload of exhaust backpressure will cause following adverse effect Output power loss Fuel efficiency reduce Exhaust gas temperature rise Note When more than one generator set are installed try not to discharge all of the generator sets gas from one e...

Page 17: ... the liquids in a separate container evenly and then add the mixture into the radiator ensure the anti freeze will not freeze under low temperature In the area when there is low possibility of freezing the coolant can be a mixture of water and anti rust according to the anti rust which recommended by the engine supplier and refer to its operation manual mix the liquids in a separate container even...

Page 18: ... specification as that existing in the radiator For some generator sets installed with coolant filter please open the filter s valve before put into use 2 7 Lubricant system Lubricant system is composed of oil pan oil pump strainer oil pipe oil cooling unit oil filter unit and the oil path inside of the engine and all kinds of lubricant parts which are in relative motion etc The main purpose of th...

Page 19: ...tor sets provide base frame style fuel tank for customer The base frame style fuel tank is installed with fuel tank fuel pipes and fuel level indicator This fuel supply system does not need customer to make other installations Customers only need to add fuel to the base frame Users who intend to self manufacture the fuel tank shall use stainless steel or steel plate to make the backup tank do not ...

Page 20: ...s are required to correctly connect the signal line to this control panel details see the control panel operation manual Automatic transfer panel optional is the automatic transfer switch for transfer between generator set and mains details refer to control panel operation manual 2 9 Battery Our generator set standard configuration provides start battery as accessory parts According to user s diff...

Page 21: ...must be connected to an earth ground Since the set is mounted on vibration isolators the ground connection must be flexible to avoid possible breakage due to vibration Ground connection cables or straps should have at least full load current carrying capacity and meet applicable regulations 2 10 3 Insulation Test Before starting the generating set after installation test the insulation resistance ...

Page 22: ...Start Part of the generator set control panel has been furnished with idle speed full speed transfer switch users can choose if the engine need to be started in idle speed or in one time full speed Usually the time period for idle speed shall not exceed five minutes Do not run the generator set in idle speed in a long time period Press on the start button the duration shall not exceed 30 seconds e...

Page 23: ...ning situation and if there is any malfunction warning generator set shut down etc Only when the correct and complete record for running maintenance has been kept very well the user can get correct and excellent after sales warranty service 3 5 Matters need attention Warning When engine s temperature is very low the time period for idle speed shall be properly extended However when the generator s...

Page 24: ...s number 3 times the Alarm LCD would flash If you need to restart wait at least 30 seconds before the retry 8 Check the reading of Voltage Meter and Frequency Meter by operating the Voltmeter Change Over Switch Once the generator set is running at the correct voltage and frequency Turn the Generator set main circuit breaker to ON 9 Turn on every switch or circuit breaker of loads from heavy to lig...

Page 25: ...light means AMF controller is active then user can select operation type OFF MAN AUTO MEASUREMENT A OFF mode Start stop mains power on off generator set power on off is inactive in this mode B MAN mode 1 Press start pushbutton to start engine 2 When output voltage is in the set range a Press mains power on off pushbutton to turn on the switch b Press mains power on off pushbutton the switch will b...

Page 26: ... if generator set is used for self start standby power In order to achieve full automatic transfer between mains power and generator set power to guarantee all load present our ATS panel select the best ATS for all generator set And to the most possibility to serve our customers demand we prepare two types of ATS MRS and AMF Besides MRS and AMF can be jointed to a double standby ATS after a little...

Page 27: ...TO that is OK detail operate step refer module control system ATS PANEL introduction No MODEL 1 ATS switch 2 panel lock 3 mains power output hole 4 generator power output hole 5 communicate with generator module port 6 load power cable output 7 panel on ground leg Maintenance inspect or exchange parts attention Attention All operator must be professional electrician Turn switch on OFF position mak...

Page 28: ... battery For each 50 600 hours of running or at least each 12 months Change lubricant and lubricant filter Because the quality of lubricant oil sulfur content of the fuel and lubricant consumption rate of each engine is different the interval for lubricant oil change for each generator set will be different When change the lubricant oil at the same time oil filter needs to be changed otherwise the...

Page 29: ... refer to Control Panel Operation Manual for details 4 5 Start battery Batteries which have been stored in a long time shall be properly charged before being used so that to ensure normal capacitance of the battery Densimeter can be used to check the actual capacitance of the battery Normal operation and battery charging will cause some water inside of the battery being vaporized And therefore con...

Page 30: ...liminate the malfunction s Especially important for new generator set s customer One thing must to be emphasized most of the malfunctions are caused by user s improper installation operation and maintenance Users are entitled to doubt that the malfunction s is caused by the generator set s manufacture failure but this conclusion shall be based on correct installation operation and periodically mai...

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Page 39: ...APPENDIX E 1 ...

Page 40: ...2 ...

Page 41: ...3 ...

Page 42: ...t running record TIME ENGINE PARAMETER GENERATOR PARAMETER IF RECORD FOR MALFUNCTION IS AVAILABLE OPERATOR REMARK Start stop generator set time Accumulated running time Oil pressure Temperature Voltage Current Frequency Power ...

Page 43: ...t serial No Engine serial No Alternator serial No Accumulated running hours Maintenance cycle Reasons for maintenance periodic maintenance or malfunction maintenance Inspection and repair Inspection and adjustment Change of parts Clean and maintenance Others Conclusion for maintenance Maintenance staff signature ...

Page 44: ...APPENDIX H ...

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