Aksa ALP 10-6 Installation & Operation Manual Download

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INSTALLATION RECOMMENDATIONS

OPERATION MANUAL

OF DIESEL GENERATING SETS

www.aksa.com.tr

Lister Petter & Perkins

Summary of Contents for ALP 10-6

Page 1: ...INSTALLATION RECOMMENDATIONS OPERATION MANUAL OF DIESEL GENERATING SETS www aksa com tr Lister Petter Perkins ...

Page 2: ... manual is designed and developed to make you familiar with the generator system This manual gives general information about mounting operation and maintenance of the generating set Tables and diagrams are also available outlining your generating set Never operate maintain or repair your generating set without taking general safety precautions ...

Page 3: ...ank 4 9 3 Fuel Lines 4 10 Lubrication Oil 4 10 1 Oil Performance Properties 4 10 2 Recommended Oil Properties for Perkins Diesel Engines 4 10 3 Lubrication Oil Recommendations by Lister Petter 4 11 Batteries 4 11 1 Maintenance Batteries 4 11 1 1 First Filling of Acid Water to The Battery 4 11 1 2 Battery Maintenance 4 11 1 3 Testing the Battery 4 11 1 4 Hydrometer Test 4 11 2 Maintenance Free Batt...

Page 4: ...NG SET CONTROL SYSTEMS 10 1 Control Panels 10 2 Manual Control System ME40 10 2 1 DSE 701 Module Features 10 2 2 DSE 701 Module Emergency Led s 10 3 Automatic Control System P 300 Panel Specifications 10 3 1 DSE 720 Module Features 10 4 Automatic Control System P 2020 Panel Specification 10 4 1 DSE 5220 Module Features 10 5 Autostart Control System P 2010 Panel Specification 10 5 1 DSE 5210 Module...

Page 5: ...dirty and dusty environments in order to keep the generating set in good working condition Necessary adjustments and repairs should be made only by authorized and qualified persons Each generating set has a model and a serial number indicated on a label on the base frame This plate also indicates the manufacturing date voltage current power in kVA and kW frequency power factor and weight of the ge...

Page 6: ...is unsafe put danger notices and disconnect the battery negative lead so that it cannot be started until the condition is corrected Disconnect the battery negative lead prior to attempting any repairs or cleaning inside the enclosure Install and operate this generating set only in full compliance with relevant National Local or Federal Codes Standards or other requirements Fuel and fumes associate...

Page 7: ...cal treatment immediately Do not induce vomiting if fuel is swallowed For skin contact wash with soap and water Do not wear clothing that has been contaminated by fuel or lube oil Wear an acid resistant apron and face shield or goggles when servicing the battery If electrolyte is spilled on skin or clothing flush immediately with large quantities of water 3 Fuels oils coolants lubricants and batte...

Page 8: ...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 securely in place Connect the generating set only to loads and or electrical systems that are compatible with its electrical characteristics and that are within its rated capacity Keep all electrical equipment clean and dry Replace any wiring where the in...

Page 9: ...il medical help takes over If condition improves confirm pulse and continue with breaths Check for pulse after every 10 breaths When breathing restarts place the victim into the recovery position described below Turn the victim onto the side Keep the head tilted with the jaw forward to maintain the open airway Make sure the victim cannot roll forwards or backwards Check for breathing and pulse reg...

Page 10: ...nator item 5 For 12 volts electrical system one battery is given For 24 volt system two lead acid batteries are given Other types of batteries may be fitted if they were specified The engine cooling system is either air cooled or water cooled The air cooled system consists of a high capacity fan to pull cool air across the engine to cool it The water cooled system is comprised of a radiator item 6...

Page 11: ...n No 1 2 3 4 No 5 6 7 8 No 9 10 11 12 Aksa generating set rating label Diesel engine Air filter Battery Description Description Battery charging alternator Radiator Alternator Terminal box Baseframe Fuel tank inside the baseframe Vibration isolators Control panel ...

Page 12: ...ion from exposure to airborne contaminants such as abrasive or conductive dust lint smoke oil mist vapors engine exhaust fumes or other contaminants Floor of generating set room must be smooth and strong Protection from impact from falling objects such as trees or poles or from motor vehicles or lift trucks 4 4 LOCATION The generating set baseframe is specifically designed for ease of moving the s...

Page 13: ... generating set fuel storage and accessories If the floor may be wet from time to time such as in a boiler room the pad should be raised above the floor This will provide a dry footing for the generating set and for those who connect service or operate it It will also minimize corrosive action on the baseframe Air for engine combustion must be clean and as cool as possible Normally this air can be...

Page 14: ... or hazard and to reduce noise A suitable exhaust silencer must be incorporated into the exhaust piping to reduce the noise level from the engine See Figure 4 4 4 5 4 8 EXHAUST Ensure hot exhaust silencers and piping are clear of combustible material and are guarded for personnel protection per safety requirements Ensure that fumes from the exhaust outlet will not be a hazard In designing an exhau...

Page 15: ...stretching elements should be used See Figure 4 5 Exhaust system components located within the generator room should be insulated to reduce heat radiation and noise levels Pipes and the silencer whether located inside and outside the building should be located well clear of any combustible material The outer end of the exhaust pipe if horizontal should be cut at 60 to the horizontal or should be f...

Page 16: ...ts Table 4 1 Aksa open type diesel look figure 4 5 genset room gen sets dimensions room dimensions air inlet and outlet openings dimensions and exhaust pipe dimensions Please contact us for gen sets which have remote radiator system ALP 8 ALP 12 ALP 15 ALP 18 ALP 22 ALP 30 AP 500 AP 550 Generating Sets Model Standby Dimensions m Room Dimensions m Power kVA Length D E K Radiator Hot Air Outlet Open...

Page 17: ...y be located outside the building where it will be convenient for refilling cleaning and for inspection It should not however be exposed to freezing weather because fuel flow will be restricted as viscosity increases The tank may be located either above or below ground A vent must be installed on the bulk tank to relieve the air pressure created by filling the tank or created by evaporation and ex...

Page 18: ... line Vent Contents gauge Bulk storage tank Sludge drain Bund tank Outlet valve Supply line to day tank Electric fuel transfer pump 11 12 13 14 15 16 17 18 19 20 Figure 4 6 Typical fuel installation using a base tank fed from a bulk tank RECOMMENDATIONS FOR FUEL PIPING Generator Stand By Power kVA Maximum Fuel Pipe Length m Maximum Vertical Height m Maximum Pipe Fittings Quantity Recommended Pipe ...

Page 19: ... pump and it will be usefull for healthy working of the engine In the simplest tank settlement the fuel level should not be above the injectors and should not be lower than the fuel pump for more than 1 8 m see Figure 4 7 Figure 4 10 Fuel tank which is put below 1500 mm If the fuel tank is set 1 5 meters above injectors two check valves must be connected like in Figure 4 8 in order to prevent the ...

Page 20: ...l Lister Petter Perkins Engines Recommends API CG4 Table 4 4 Coolant and oil capacities and lubricating oil specifications 50 Hz Gen sets 5 5 6 5 5 5 7 5 6 5 7 5 50 50 1 9 2 8 3 9 3 8 5 9 7 8 97 108 LPW 2 LPW 3 LPW 2 LPW 4 LPW 3 LPW 4 2506A E15TAG2 2506A E15TAG1 Generating Sets Model Engine Model Oil Specifications Stand by Power kVA Lt L h Fuel Tank Capacity Fuel Consumption at Full Load Coolant ...

Page 21: ...g This will prevent electrical losses from long cale that could impact on the engine starting capability of the batteries 4 11 BATTERIES 1 2 3 4 5 6 7 The American Petroleum Institute API the American Society for Testing and Materials ASTM and Society of Automotive Engineers SAE has developed and preserved a system in order to classify the lubrication oils for their performance categories 17 Tempe...

Page 22: ...tery terminals and its connections with vaseline Tighten the terminals but not tighten it hardly Control the electrolyte level periodically It must be 10 mm above the plates Control the abrasion in the charge alternator belt and check periodically the belt tension according to the producer s recommendation Ensure that your battery is not uncharged 4 11 1 2 Battery Maintenance Conduct an inspection...

Page 23: ...load the generator The set will provide its kilowatt rating and operate satisfactorily from 0 8 lagging to unity power factor 1 0 Particular attention must be given to installations with power factor correction equipment such as capacitors to ensure that a leading power factor is never present This will lead to voltage instability and may result in damaging overvoltages Generally whenever the gene...

Page 24: ...r Ampere Cable Section YVV 25 ºC mm2 Lister Petter Perkins 12 17 21 23 31 43 720 792 Full Load Current U 400 Vac Cosj 0 8 GENERATING SETS ALP 10 6 ALP 15 6 ALP 21 6 AP 565 6 AP 616 6 Model Full Load Current U 400 Vac Cosj 0 8 Current Capacity of Cable at Air 40 C ambient temperature Ampere Lister Petter 10 15 21 565 616 14 4 21 6 30 816 890 22 30 38 1068 1068 2 5 4 6 4x120 4x120 Stand by Power kVA...

Page 25: ...acoustic louvers splitter vents and fan silencers as well as 4 13 ACOUSTIC SILENCING sound absorbing wall coverings that can be used to reduce the noise levels of generating sets Jacket water heater is used in order to startup the generating set more easily and to take the load In automatic generating sets jacket water heater is standard In manual type generating sets it is an option Heater warms ...

Page 26: ...e the battery is stored it should receive a refreshing charge every 8 weeks up to a fully charged condition A good maintenance program is the key to long generating set life The recommended maintenance program is provided on the Periodic Maintenance Chart This chart is given with all generating sets Maintenance and service should only be carried out by qualified technicians The maintenance and ser...

Page 27: ...nsferred to the generator and the set will run on load untill Auto mode is selected or Stop is pressed Selecting Stop de energises the fuel solenoid bringing the generator to a stop 7 3 STARTING WITH P300 AUTOMATIC CONTROL PANEL The DSE 720 automatic mains failure controls generating set system Module has been designed to monitor the mains utility supply 7 3 1 Manual Operation This mode is activat...

Page 28: ...ected by panel lock To initiate a start sequence in MANUAL press the pushbutton When the controller is in the manual button pressing the START 1 button will initiate the start sequence NOTE There is no Start Delay in this mode of operation The Fuel Solenoid is energized then the Starter Motor is engaged The engine is cranked for a preset time period If the engine fails to fire during this cranking...

Page 29: ... the Fuel Solenoid bringing the generator to a stop 7 5 2 Automatic Mode of Operation NOTE If a digital input configured to panel lock is active the LCD will display the icon When in panel lock changing modules will not be possible Viewing the instrument and event logs is not affected by panel lock This mode is activated by pressing the push button An LED indicator beside the button confirms this ...

Page 30: ...s and event logs is not affected by panel lock To initiate a start sequence in TEST press the pushbutton When the controller is in the test mode indicated by an LED indicator beside the button pressing the START 1 button will initiate the start sequence NOTE There is no Start Delay in this mode of operation The Fuel Solenoid is energized then the Starter Motor is engaged The engine is cranked for ...

Page 31: ...2 MANUAL CONTROL SYSTEM ME 40 10 2 2 DSE 701 MODULE EMERGENCY LED s High engine temperature shutdown Low oil pressure shutdown Over speed shutdown Charge failure warning 10 2 1 DSE 701 MODULE FEATURES Engine supervision and protection Key switch operation on the fron panel Figure 10 2 DSE 701 Manuel Control Module Figure 10 1 ME 40 Manual Control Panel Control with DSE 720 Automatic Mains Failure ...

Page 32: ... Under Over mains frequency Emergency stop Low oil pressure Led indications Mains available Generator available Mains on load Generator on load Figure 10 3 DSE 720 AMF Control Module Under over generator volts Pre Alarm and Shutdown Under over generator frequency Pre Alarm and Shutdown Under over mains volts Under over mains frequency Over current Shutdown Low oil pressure Pre Alarm and Shutdown H...

Page 33: ...hutdown Under over generator frequency Pre Alarm and Shutdown Over current Shutdown Low oil pressure Pre Alarm and Shutdown High engine temperature Pre Alarm and Shutdown Under over speed Shutdown Low coolant level Shutdown Fail to start Shutdown Fail to stop Warning Low High Battery volts Warning Charge fail Warning Emergency stop Shutdown Multiple Alarms 5220 control module maintains a log of th...

Page 34: ...Frequency Meter A meter that indicates the total number of hours of generating set operation to aid in maintenance 10 6 5 Hours Run Meter A temperature gauge connected to a sensor in the engine to monitor engine coolant temperature Normal level of the engine coolant temperature is approximately 85ºC 185ºF 10 6 6 Water Temperature Gauge A gauge to monitor engine oil pressure from the moment the eng...

Page 35: ...s KiloWatts Hours Run Timer in progress Configuration mode active Panel locked by configurable input L1 L1 N L1 L2 BAR V A kW L3 L1 N L3 L1 PSI Hz RPM Cosj Display Description Display Description Display Description Display Description Display Description Display Description Warning Alarm Fuel Charge Fail Emergency Stop Over Voltage DC Under Voltage DC Auxiliary Indication Shutdown Alarm Low Oil P...

Page 36: ...possible Current from one phase should not exceed the nominal current Figure 11 Typical emergency power system installation Current from one phase should not exceed the nominal current Two different power cables which will be used between the generating set and the transfer switch is on the generating set Main supply cable and power cable for emergency power panel If the transfer switch panel is a...

Page 37: ...8 software to configure function Start Delay Active LED Indicates that the 530 internal start delay timer is running Once expired the start signal will be given to the generator controller Mains Return Timer Active LED Indicates that the 530 s internal mains return timer is running Once expired the load will be transferred back to the mains supply AUTO If the module is placed in AUTO mode it will ...

Page 38: ...engine speed Check wingings High voltage at no load Voltage potentiometer out of setting Failed regulator Reset voltage Substitude regulator Failed regulator Rotating bridge failure Substitude regulator Check diodes disconnect cables Higher than rated voltage at load Voltage potentiometer out of setting Failed regulator Reset voltage potentiometer Substitude regulator Unstable voltage Speed variat...

Page 39: ...old start system Wrong type or grade of fuel used Restriction in exhaust pipe Engine temperature is too low Incorrect valva tip clearances Engine over load Blue or white exhaust smoke Wrong grade of lubrication Fault in cold start system Engine temperature is too low The engine knocks Fault in fuel lift pump Fault in atomisers or atomisers of an incorrect type Wrong type or grade of fuel used Faul...

Page 40: ...RANTY ON MANUAL GENERATING SETS NEVER START OR STOP THE DIESEL ENGINE WHEN THE GENERATING SET IS UNDER LOAD ENGINE SHOULD BE STARTED AND STOPPED AFTER LOAD IS DISCONNECTED AND THE GENERATING SET IS AT IDLE CONDITION OTHERWISE THE VALVES CAN BE SEIZED THE VOTAGE REGULATOR TRANSFORMER AND DIODES CAN BE BROKEN DOWN THESE CONDITIONS ARE NOT COVERED BY THE WARRANTY OUR COMPANY DOES NOT TAKE THE RESPONS...

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Page 50: ...30 837 472 Fax 44 1530 519 577 e mail sales aksa uk com CHINA Aksa Chine Suzhou Zhongxin City 128 Donghuan Road Room 706 Suzhou China 215021 P R China Tel 86 512 6725 1137 Fax 86 512 6725 1317 IRAN Aksa Iran Apt 22 the 5th Floor Dasto Building No 1421 Vali e Asr Ave Tehran Iran Tel 98 21 2205 4212 2201 6502 Fax 98 21 2201 8921 e mail aksatehran gmail com DUBAI UAE Aksa Middle East Post Box No 1816...

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