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Diesel Gen-set Operation Instructions

Alternator is a device converting mechanical energy into electrical energy.

1. Structure of alternator

The Weichai Gen-set adopts a brushless three-phase synchronous alternator. As

shown in Figure 3-2, the alternator mainly consists of main stator (armature), main

rotor (magnetic field), exciter stator (magnetic field), exciter rotor (armature), rotary

rectifier, automatic voltage regulator (AVR) and outlet box, etc.

Figure 3-2 Sectional view of alternator

2. Operating principles of alternator

After alternator is driven, main stator (armature) generates certain remanence voltage,

automatic voltage regulator (AVR) outputs a remanence current to exciter stator

(magnetic field) after obtaining remanence voltage from main stator (armature),

exciter rotor (armature) generates three-phase alternating current which is then

transmitted to main rotor (magnetic field) excitation winding after being rectified into

direct current by rotary rectifier, in order to enhance magnetic field of main rotor and

increase voltage of main stator (armature). By constant cycling of this voltage buildup

process, alternator builds up rated voltage steadily in a short time.

Rotary rectifier

Optional permanent

magnet alternator

Coupling

Fan

Main rotor
(magnetic field)

Main stator (armature)

Stator alternating

current output

Bearing

Permanent magnet

stator (armature)

Permanent magnet

alternator rotor

(magnetic field)

Exciter stator (magnetic

field)

Exciter rotor

(armature)

Installation of

coupling

Содержание WPG13.5

Страница 1: ...Operation Maintains Manual of Weichai Group Diesel Gen set Version No V01 Weichai Heavy Machinery Co Ltd...

Страница 2: ...unctions in order to ensure that the equipment can be put into normal operation rapidly Please refer to and read diesel engine s operation manual alternator s user manual and drawings and documents of...

Страница 3: ...RANGE OF APPLICATION 7 CHAPTER 3 OVERVIEW ON MAIN STRUCTURE OF THE GEN SET 8 I DIESEL ENGINE 8 II ALTERNATOR 8 III CONTROL PANEL 16 CHAPTER 4 MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS OF THE GEN SE...

Страница 4: ...CTIONS BEFORE OPERATION 55 II OPERATION OF THE GEN SET 56 CHAPTER 9 MAINTENANCE AND CARE OF THE GEN SET 60 I MAINTENANCE AND CARE SCHEDULE 60 II MAINTENANCE AND CARE OPERATION 61 CHAPTER 10 COMMON FAI...

Страница 5: ...operators caused by live casing Because Weichai Gen set is designed with safe grounding system customers only need to install as per local electric power rules and regulations 1 2 Do not open cover pl...

Страница 6: ...ating parts and cause personal injuries or even death 3 3 Keep your hands away from rotating parts when the Gen set is operating 4 High temperature parts may cause injuries of operators 4 1 Do not ope...

Страница 7: ...as shown in Table 1 1 Table 1 1 Meanings of safety symbols used on Weichai Gen set No Symbols Description 1 A warning meaning that there is some immediate danger that may cause serious injuries or eve...

Страница 8: ...ation Instructions 4 8 Beware of hot surface 9 Beware of electric shock 10 Beware of rotating parts 11 Beware of auto starting 12 Must be grounded 13 Lift up the Gen set from here 14 Transport with a...

Страница 9: ...sting of four parts is named as per following rules II Description on power of the Gen set 1 Rated power it refers to the maximum power that the Gen set is able to provide continuous power supply to v...

Страница 10: ...itions rated power of the Gen set shall be corrected If the load power of the Gen set during operation is greater than corrected rated power the diesel engine will belch a lots of black smoke and beco...

Страница 11: ...nt site conditions must be taken into consideration also during model selection When the Gen set is going to be used under non standard environmental conditions users shall correct power of the Gen se...

Страница 12: ...er inlet of radiator 16 Radiator 17 Batteries Remarks B series gen set without fuel tank and fuel level indicator Fig 3 1 Structural schematic diagram of the Gen set The Gen set mainly consists of die...

Страница 13: ...ts a remanence current to exciter stator magnetic field after obtaining remanence voltage from main stator armature exciter rotor armature generates three phase alternating current which is then trans...

Страница 14: ...liable way Weichai 10 50kW Gen set is equipped with AS440 BE350 AS480 type AVR type of AVR is clearly marked on nameplate of alternator Structure and function of AVR are described below respectively P...

Страница 15: ...he alternator is equipped with auxiliary winding they shall be disconnected and connected to auxiliary winding 2 As shown in Figure 3 5 terminal 7 and 8 are connected to main stator armature of altern...

Страница 16: ...bility adjustment shall be selected as per Table 3 1 Table 3 1 Stability selection list Serial number Power range Response speed B D 100kW Slow A C 100kW Fast B C 100 550kW Fast A B 550kW Fast 7 Frequ...

Страница 17: ...crease analog input sensitivity Turn clockwise to increase gain or sensitivity 4 Over excitation tripping Set over excitation tripping trigger potential Turn clockwise to increase tripping trigger pot...

Страница 18: ...nput range is 171 264Vac and power input is connected to terminal 3 and 4 3 3 AS480 Figure 3 7 AS480 structure and wiring diagram 1 Terminal 7 and 8 are connected to main stator armature of alternator...

Страница 19: ...droop Stability Prevent voltage swing Turn clockwise to increase damping effect UFRO Under Frequency Roll Off Set UFRO knee point Turn clockwise to decrease knee point frequency 3 4 Regulating method...

Страница 20: ...rnator is stable but it is also very close to unstable zone III Control panel Control panel is brain of the Gen set as it not only enables starting stopping data measurement data display and fault pro...

Страница 21: ...kVA kW PF kVAR kWh kVAH and kVARH parameters of mains power frequency three phase voltage L L and L N contains 7 inputs and 6 outputs 4 outputs can be customized in MPU version and 6 outputs can be c...

Страница 22: ...n 3 Press this button to display detail information of current page 4 Stop operation of Gen set 5 Press this button to enter into manual mode and adjust parameters 6 Simulate state of loss of mains po...

Страница 23: ...ncy stop button Press this button to stop the Gen set immediately when any emergency occurs And the Gen set is unable to be started under this state When the emergency situation is over the Gen set ca...

Страница 24: ...tery voltage parameters of alternator frequency three phase voltage L L and L N and current power parameters of alternator kVA kW PF kVAR kWh kVAH and kVARH parameters of mains power frequency three p...

Страница 25: ...et Operation Instructions 21 Figure 3 11 DSE6020 module No Function 1 Gen set stop and fault resetting button 2 Gen set manual mode button 3 Mains power fault simulation and test button 4 Gen set AUTO...

Страница 26: ...on 10 Left and right menu navigation button used to select menu in turn 11 Up and down selection button used to query parameters in each menu in turn LED indicator light 12 When generated electricity...

Страница 27: ...e 4 LED indicator lights are customized according to actual needs in 16 19 and these 4 LED indicator lights customized here are taken as an example only 2 Power switch Control power on off of control...

Страница 28: ...Diesel Gen set Operation Instructions 24 3 Electrical schematic diagram Figure 3 12 Electrical Schematic Diagram of DSE6020 Module s Common Functional Gen set Mechanical Governing...

Страница 29: ...Diesel Gen set Operation Instructions 25 Figure 3 13 Electrical Schematic Diagram of DSE6020 Module s Automatic Change Over Gen set Mechanical Governing...

Страница 30: ...Diesel Gen set Operation Instructions 26 Figure 3 14 Electrical Schematic Diagram of DSE7320 Module s Automatic Gen set Mechanical Governing...

Страница 31: ...Diesel Gen set Operation Instructions 27 Figure 3 15 Electrical Schematic Diagram of DSE7320 Module s Automatic Gen set Mechanical Governing...

Страница 32: ...lagging 0 8 0 8 0 8 0 8 0 8 0 8 0 8 0 8 Coolant volume L 10 12 11 3 15 9 15 9 14 8 14 8 17 Lubricating oil volume L 8 5 8 5 7 5 11 11 11 11 13 Maximum allowable exhaust back pressure kPa 6 6 6 6 6 6...

Страница 33: ...equency Hz 50 50 50 50 50 50 50 50 Rated current A 18 22 29 36 44 55 73 91 Rated speed r min 1500 1500 1500 1500 1500 1500 1500 1500 Rated power factor lagging 0 8 0 8 0 8 0 8 0 8 0 8 0 8 0 8 Coolant...

Страница 34: ...12 12 12 12 12 Battery capacity A h Shuangdeng 40 40 40 40 40 40 40 40 Cooling area mm 498 415 498 415 498 415 498 415 498 415 498 415 498 415 498 415 Note 1 Above main specifications and technical p...

Страница 35: ...set can prevent the Gen set from being suffered from damages caused by external shocks effectively In addition the Gen set shall be firmly secured during transportation in order to prevent loosening o...

Страница 36: ...set and its accessories are damaged or rusted or not The Gen set after being unpacked must be positioned horizontally and flanges and various joints must be sealed in order to prevent intrusion of moi...

Страница 37: ...5000mm L 4000mm W 3500mm H 2 Requirements for foundation Foundation of the Gen set must meet following requirements 1 Able to support total wet weight of Gen set including the Gen set accessory equipm...

Страница 38: ...ition these steel wire ropes shall have enough strength and carrying capacity of lifting tools shall meet requirements of safety specifications When being lifted the Gen set shall be kept horizontal a...

Страница 39: ...d ground and improve cushioning function Suggestion fix with anchor bolts because anti vibration pads would be worn and deformed after long period of service causing working plane of the Gen set to be...

Страница 40: ...uel consumption exhaust temperature and emission shall be increased In order to reduce exhaust back pressure following measures shall be taken 1 Number of elbow shall be reduced as much as possible an...

Страница 41: ...t away from engine silencer and any section of the pipe where condensed liquid exists e g vertical turn of exhaust pipe shall be equipped with outlet 6 6 Position of exhaust outlet shall be designed a...

Страница 42: ...e 1 Diameter of fuel pipe depends on inlet diameter of fuel injection pump and shall be the same with inner diameter of inlet at least if it is far in distance diameter of the pipe shall be increased...

Страница 43: ...so Weichai recommends you to select cable as per following specifications Table 6 1 Specifications of power cable of the Gen set No Power of the Gen set kW Specifications of copper core insulated cabl...

Страница 44: ...s usually not live when any leakage current is produced Besides casing of the Gen set shall be grounded in order to provide personnel protection for operators In order to improve reliability of electr...

Страница 45: ...Diesel Gen set Operation Instructions 41 Lighting facilities equipment room shall be equipped with necessary lighting facilities...

Страница 46: ...nlet louver Concrete floor Fire fighting equipment Hot air Air direction pipe Gate of equipment room Air exhaust window Exhaust pipe Silencer Exhaust pipe suspension Cable trench to power distribution...

Страница 47: ...the wire and check if the connection is loose or damaged or not If any tighten or replace it 4 Check reliability of fasteners and throttle control system confirm if various operating mechanisms are f...

Страница 48: ...Gen set Anti freeze is one kind of coolant containing special additives Anti freeze refilled in engine has following functions 1 Ensure that engine operates in a normal temperature range 2 Prevent co...

Страница 49: ...y from bright sunlight 1 2 Method for refilling of coolant Slowly fill coolant into cooling system from filler on radiator until level of coolant in radiator is 5cm away from filler in order to bleed...

Страница 50: ...y base oil and well chosen additives and sold by various service outlets at a unified price in China Note Do not use CD grade or below lubricating oil on the Gen set Be sure to replace engine oil filt...

Страница 51: ...on of grade as per GF252 2000 is as shown below No 10 light diesel oil applicable for diesel engine with preheating equipment No 5 light diesel oil applicable for the regions where lowest air temperat...

Страница 52: ...ed as the fuel Warning when filling fuel to fuel tank do not smoke or use open flame nearby because this usually would cause a risk of fire or exploration 3 3 Fuel system bleeding During first commiss...

Страница 53: ...ubrication system cooling system and other systems of diesel engine are free from fuel leakage and water leakage 5 Connection of loaded cable Connect loaded power cable to air switch of the Gen set ac...

Страница 54: ...sulation resistance to ground of F1 and F2 wiring on AS440 and AS480 for SE350 measure insulation resistance to ground of F and F 5 The resistance value shall be greater than 5M If not be sure to dry...

Страница 55: ...If you want to stop the Gen set press stop button Note do not start the Gen set when being loaded namely air switch shall be in switching off position when the Gen set is started Note if starting is n...

Страница 56: ...k operation state of the Gen set again Main checking contents are as follows 1 Check speed and frequency of the Gen set normal speed and frequency of the Gen set is separately 1530 1560r min and 51 52...

Страница 57: ...andle to increase speed of diesel engine to approximately 1 500r min frequency 50Hz 2 Check voltage of three phase output line of the Gen set Voltage of each line shall be 400V 3 Check three phase cur...

Страница 58: ...wer switch to OFF position to cut off power supply of the entire control system 4 Remove connecting cable from negative electrode of battery and protect it with insulation tape 3 2 Emergency stop In a...

Страница 59: ...eplace it 4 Check reliability of fasteners and throttle control system confirm if various operating mechanisms are flexible portable and reliable and check pre tensioning of charger belt and fan belt...

Страница 60: ...ation without load at rated speed for 120s If you want to stop the Gen set directly press stop button two times directly Note do not start the Gen set when being loaded namely air switch shall be in s...

Страница 61: ...quency of the Gen set normal speed and frequency of the Gen set is separately 1530 1560r min and 51 52Hz 2 Check three phase output voltage of the Gen set and the value shall be 400V 3 Check current o...

Страница 62: ...ot have an impact on system operation of engine but only is used to remind operators of the conditions that do not meet with requirements When any warning occurs display panel will display correspondi...

Страница 63: ...stop control handle is rapidly pushed to OFF position Emergency stop signal will be released only this button is pressed again Emergency stop must be activated immediately after any of the followings...

Страница 64: ...dirt on electric brush and commutator of starter and lubricate bearing of alternator 200h Change engine oil and element of oil filter Check water dropping condition at drain hole of water pump If it...

Страница 65: ...1 Checking fuel engine oil and coolant level Fuel level never operate the Gen set when fuel level is lower than lower scale mark Fill proper amount of diesel oil into chassis fuel tank or daily use f...

Страница 66: ...nd prepare a vessel to collect drained engine oil Immediately open oil drain valve on oil pan to drain engine oil and impurities fully during which burns shall be paid attention to and prevented 2 2 R...

Страница 67: ...he upper and lower scale mark of oil dipstick 3 Replacing fuel filter 3 1 Turn off the engine to let it cool down in order to avoid damage from heat 3 2 Prepare a vessel to collect leaked fuel 3 3 Rem...

Страница 68: ...en performance of radiator will be influenced further The common method to remove these tiny impurities is to spray low pressure steam flow into it The impurities which are difficult to be removed sha...

Страница 69: ...or drain plug at bottom 6 Check if there is any rust scale in water tank If any increase concentration of the solvent to 8 and repeat above procedures 7 After rust removal neutralize this acid soluti...

Страница 70: ...be able to freely flows in the alternator and bring away moisture Please introduce hot air into alternator from its air intake with two 1 3kW electric hair dryers Pay attention that winding shall be...

Страница 71: ...ust voltage of direct current power source to zero at first and then start the Gen set Increase direct current voltage slowly so as that current flows in coil of excitation stator magnetic field When...

Страница 72: ...ue once every half hour and tabulate these records into a graph as shown in Figure 9 4 Figure 9 4 Typical drying curve Figure 9 4 shows typical drying curve of a very humid alternator This curve shows...

Страница 73: ...so removal of these parts is allowable only after stopping Remove parts of air filter from air filter cover and soak or wash these parts with proper oil removal agent until these parts are fully clea...

Страница 74: ...rust oil flow into combustion chamber Do not rotate crankshaft anymore once all sealing up works are completed in order to prevent oil film attached on cylinder wall from being scratched off 5 Drain v...

Страница 75: ...es do not be placed upside down or on the side and prevent from being impacted or weighted After long period of service the battery itself may discharge slowly or even scrap Therefore in order to ensu...

Страница 76: ...el tank Stop handle is in stop position and does not operate during starting Check relay and line troubles Stall controller malfunctions Contact with after sale service personnel to maintain or replac...

Страница 77: ...ice personnel to maintain Insufficient cylinder compression pressure caused by wear of piston ring Replace piston ring Supercharger malfunctions Repair or replace supercharger Thin air caused by extre...

Страница 78: ...a Gen set with proper power Piston ring is stuck or worn excessively and less in elasticity or engine oil enters into combustion chamber Replace piston ring 3 White smoke there is water in diesel oil...

Страница 79: ...tion of oil fluid Check if amount of engine oil in oil pan is too march and lubricating oil return pipe of speed regulator is blocked or not and have it cleaned and replaced when necessary 4 Various c...

Страница 80: ...Rated speed Remanence voltage is low Magnetize as shown below Other reasons Check alternator and AVR as per procedures of excitation separation as shown below 2 Voltage is unstable in loaded or no lo...

Страница 81: ...tator magnetic field to the AVR outlet box If the measured voltage is more than 5V the alternator should run normally If the measured voltage is less than 5V execute the following steps Use 12V DC cur...

Страница 82: ...ter is used to set the knee point Inappropriate setting will lead to the following consequences A light emitting diode LED on the top of UFRO control potentiometer is on with load Voltage regulation f...

Страница 83: ...and F2 or F and F of AVR 4 Rotate voltage control potentiometer on AVR clockwise to the end 5 Connect 12V1 0A DC power source to F1 and F2 or F and F of lead of magnetic field Note that positive elect...

Страница 84: ...sed diode and positive plate with forward biased diode Note that polarity of diode installed onto corresponding plate must be correct Good mechanical and electrical connection shall be guaranteed for...

Страница 85: ...n hot state 2 Load power is more than rated power of Gen set Reduce load or select Gen set of higher rated power 3 Air is thin due to too high temperature or altitude Consult salesmen about correcting...

Страница 86: ...s 20 Oil circuit is blocked Inspect and clean and replace if necessary 21 Air in the oil circuit causes too great fluctuation of injection pressure Discharge air in low pressure and high pressure oil...

Страница 87: ...ing of valve or breakage of piston Immediately stop for overhaul 9 Squealing of air leakage is made at cylinder head gasket Inspect bolt pretightening force of cylinder head and replace the cylinder g...

Страница 88: ...fork which keeps the plunger at maximum oil level Contact with after sales service personnel for repair 4 Oil supply control rack and moving parts of governor suffer from clamping stagnation which di...

Страница 89: ...lace main bearing and connecting rod bearing 6 High coolant temperature Serial number Cause Elimination method 1 Coolant is insufficient Fill coolant to 5cm below the tank cover 2 Fault of water pump...

Страница 90: ...cylinder liner 3 Valve rod and guide suffer from serious wear and tear which makes machine oil enter combustion chamber Replace valve rod and guide 4 There is too much machine oil in oil pan which ma...

Страница 91: ...1616 I Service Concept Customer satisfaction is our purpose II Service Commitment The repair service center of our company guarantees to arrive at the site within 3h in the city 24h in general areas a...

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