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Operation & Maintenance Manual for WP12CD Series Marine Diesel Gen-set

Operation & Maintenance Manual for

WP12CD Series Marine Diesel Gen-set

Weichai Heavy Machinery Co., Ltd.


Foreword

Weichai Heavy Machinery Co., Ltd. is China’s appointed manufacturer of

various types of stationary gen-set and marine gen-set.

The manual provides instructions on the installation, operation, maintenance and

trouble shooting of marine gen-set according to the characteristics of WP12CD Series

marine diesel gen-set for user’s safe and reliable operation. Please refer to the

Operation Manuals for diesel engine, power Alternator and various special parts in

instrument boxes when using this manual, and operate, service and maintain it in

accordance with corresponding requirements.

Along with technical development and product improvement, changes will be

made on this manual accordingly. This manual is subject to revisions and changes

from time to time.


Contents CHAPTER I CODE REPRESENTING METHOD ................................................. - 1 -

CHAPTER II WORKING CONDITIONS ............................................................... - 1 -

I. RELIABLE WORKING CONDITIONS .............................................................. - 1 -

II. WORKING CONDITIONS FOR GEN-SET TO OUTPUT RATED POWER ... - 1 -

CHAPTER III TECHNICAL SPECIFICATIONS AND MAIN PARAMETERS ... - 2 -

I. MAIN TECHNICAL SPECIFICATIONS ............................................................. - 2 -

II. MAIN ELECTRICAL PERFORMANCE INDICATORS ................................... - 2 -

III. GEN-SET PROTECTION PARAMETERS ....................................................... - 3 -

IV．OVERALL DIMENSIONS OF GEN-SET ...................................................... - 4 -

V. GEN-SET OUTLINE DRAWING ....................................................................... - 4 -

CHAPTER IV OVERVIEW OF MAIN STRUCTURES ......................................... - 5 -

I． DIESEL ENGINE .............................................................................................. - 5 -

II. AC ALTERNATOR .............................................................................................. - 7 -

III. INSTRUMENT BOX ......................................................................................... - 7 -

IV. SOLID BASE FRAME ....................................................................................... - 7 -

CHAPTER V STORAGE AND INSTALLATION .................................................. - 8 -

I. STORAGE ............................................................................................................. - 8 -

II. UNPACKING ACCEPTANCE ............................................................................ - 8 -

III. LIFTING & HANDLING ........................................................................... - 8 -

IV. INSTALLATION ................................................................................................ - 9 -

1. Installation of gen-set external pipes .................................................................... - 9 -

2. Installation of vent-pipe ........................................................................................ - 9 -

3. Installation of fuel pipes...................................................................................... - 11 -

4. Installation of cooling pipes ................................................................................ - 11 -

5．Installation of starting system ........................................................................... - 13 -

6. Other requirements.............................................................................................. - 13 -

CHAPTER VI GEN-SET ELECTRICAL SYSTEM ............................................. - 13 -

I. INSTRUMENT BOX .......................................................................................... - 14 -

1. Local ordinary instrument box ............................................................................ - 14 -

2. Local self-starting instrument box ...................................................................... - 17 -


3. New style local ordinary instrument box ............................................................ - 22 -

4. New style local self-starting instrument box ...................................................... - 26 -

5. Onboard instrument ............................................................................................ - 30 -

6. Accelerator servo mechanism ............................................................................. - 33 -

II. ALTERNATOR .................................................................................................. - 35 -

CHAPTER VII OPERATION ................................................................................. - 36 -

I. PREPARATION .................................................................................................. - 36 -

II. COMMISSIONING ........................................................................................... - 36 -

CHAPTER VIII PARALLEL OPERATION .......................................................... - 38 -

I. CONDITIONS FOR PARALLEL OPERATION ................................................ - 38 -

II. METHODS......................................................................................................... - 38 -

III. LOAD TRANSFER IN PARALLEL ................................................................ - 39 -

IV． DISCONNECTION OF PARALLEL GEN-SET ......................................... - 40 -

CHAPTER IX PRECAUTIONS............................................................................. - 40 -

CHAPTER X ANALYSIS OF COMMON FAULTS AND TROUBLESHOOTING ... -

41 -

CHAPTER XI RULES FOR SAFE OPERATION ................................................. - 42 -

CHAPTER XII SERVICING AND MAINTENANCE .......................................... - 42 -

ANNEX I: LIST OF TOOLS DELIVERED WITH GEN-SET (EX-FACTORY

STANDARD CONFIGURATION) ........................................................................ - 45 -

ANNEX II: LIST OF SPARE PARTS DELIVERED WITH GEN-SET

(EX-FACTORY STANDARD CONFIGURATION) ............................................. - 46 -


- 1 -

Chapter I Code Representing Method

Chapter II Working Conditions

I. Reliable working conditions

Gen-set can operate reliably under following conditions:

Table 2-1 Working Conditions

1 Ambient temperature 45C

2 Outboard water

temperature

32C (Outboard water temperature of gen-set in limited navigating zone

and under corresponding conditions shall be 25C.)

3 Relative air humidity 60%

4 Absolute atmosphere 100kPa

5 Transverse inclination 15°(22.5° for emergency gen-set and inland vessel)

6 Longitudinal

inclination 7.5° (10° for emergency gen-set and inland vessel)

7 Rolling 22.5°

8 Pitching 10°

9 Able to bear the vibration and shock generated during normal sailing.

10 Having salt fog, mould, oil mist, condensing fog, damp air.

II. Working conditions for gen-set to output rated power

Gen-set should be able to continuously output rated power under following

× ×CCF

Factory design code, represented in capital lettersranging from A to Z

Code of navigation zone applicable to gen-set , W for unlimited navigation zone and Y for limited navigation zone

Gen-set classification code, J for basic type, Z for automatic type and Z for emergency type

Gen-set rated power code representing in kW

Marine diesel gen-set code

Current classification code, J for AC and Z for DC


- 2 -

working conditions:

a For gen-set in unlimited navigating zone: ambient temperature 45C, primary

cooling water temperature 32C, relative humidity 60%;

b For gen-set in limited navigating zone and under corresponding conditions:

ambient temperature 40C, primary cooling water temperature 25℃, relative humidity

60%.

Chapter III Technical Specifications and Main Parameters

I. Main technical specifications

Table 3-1 Main technical specifications

II. Main electrical performance indicators

Table 3-2 Main electrical performance indicators

Serial

No. Items Electrical indicators

1 Steady-state voltage regulation

factor ±2.5% (for emergency gen-set ±3.5%)

Serial No. Items Contents

1 Mode of gen-set CCFJ250J-W* CCFJ250J-W*

2 Diesel engine mode WP12CD317E200 WP12CD317E201

3 Rated power(kW) 250 250

4 Rated voltage (V) 400/230 440/254

5 Rated frequency (Hz) 50Hz 60Hz

6 Rated current (A) 451 410

7 Rated power factor 0.8 (lagging)

8 Rated speed (r/min) 1500r/min 1800r/min

9 Starting mode Electric motor

10 Speed regulating mode Electric speed regulation/mechanical speed regulation

11 Exciting mode Brushless self-excitation

12 Voltage regulating mode Automatic

13 Wiring mode Three-phase four-wire Y-connection

14 Cooling method Opening type bi-circulating water cooling


- 3 -

2 Transient voltage regulation

factor -15% transient voltage regulation factor +20%

3 Voltage stabilization time 1.5s

4 Voltage fluctuation ratio ±1%

5 No-load voltage setting range ≥±5% rated voltage

6 Steady-state speed regulation

factor

Electronic speed regulation 3%/(mechanical speed

regulation 5%)

7 Transient speed regulation

factor ±10%

8 Stabilization time 5S

9 Speed fluctuation ratio ±0.5%

10 110% rated load operating for 1 hour is allowed by gen-set continuously running for each

12 hours

11

Two gen-sets can maintain long-term stable parallel operation. It can maintain stable

operation and steadily transfer active power and reactive power when the load varies

within 20%-100% of total rated power against rated power factors; the active power

sharing unbalance is not greater than 15% of Alternator’s rated power and reactive power

sharing unbalance is greater than 10% of Alternator’s rated reactive power.

III. Gen-set protection parameters

Table 3-3 Gen-set protection parameters

Serial

No. Alarm description Alarm value Remarks

1 Speed is high 110% rated

speed Alarming

2 Oil pressure is low 0.12±0.02Mpa Alarming

3 Water temperature is high 95+3C Alarming

4 Oil temperature is high 102+3C Alarming

5 Speed is too high 115% rated

speed Alarming and shutdown

6 Oil pressure is too low 0.08±0.02Mpa Alarming and shutdown

7 Storage battery voltage is

low <19V Alarming

8 Fuel leakage alarm Alarming, and fuel leakage


- 4 -

(optional) alarm apparatus required

IV．Overall dimensions of gen-set

Table 3-4 Overall dimensions of gen-set

Gen-set Model L*W*H (mm) Weight (kg)

CCFJ250J-W*

CCFJ250J-WE 2610×1082×1630 2700

CCFJ250J-WI 2666×1082×1630 2150

CCFJ250J-WU 2617×1082×1630 2286

CCFJ250J-WQ 2540×1082×1630 2150

CCFJ250J-WY 2576×1082×1630 2450

Note: “*”in “W*” represents the Alternator to be used for the diesel gen-set. “*”

can be replaced by E, I, U, Q, Y, among which, E represents LD Alternator, I

represents Marathon Alternator, U represents Stanford Alternator, Q represents

Kangfu Alternator (formerly known as Sanbo Alternator) and Y represents Wuxi

Siemens Alternator.

V. Gen-set outline drawing

Outline drawing examples of CCFJ250J-W* marine diesel gen-set (standard

configuration: equipped with ordinary instrument box) are as shown in Figure 3-1,

Figure 3-2, Figure 3-3, Figure3-4 and Figure 3-5 (relevant drawings of other

configurations can also be provided according to customer’s requirements):

Figure 3-1 Front view Figure 3-2 Left view

①Belt

Fuel oil return opening

E engine oil filler


- 5 -

Figure 3-3 Rear view Figure 3-4 Right view

Figure 3-5 Top view

Chapter IV Overview of main structures

I． Diesel engine

Diesel engine is the power source of gen-set and this unit adopts Weichai

WP12CD series Alternator (please refer to Operation and Maintenance Manual for

WP12CD Series Gas Alternator for detailed structure principles). Main technical

specifications of the diesel engine are shown in Table 4-1:

Table 4-1 Main technical specifications of diesel engine

Serial

No.

Model

Items WP12CD317E200 WP12CD317E201

Intercooler cooling water inlet

Intercooler cooling water outlet

List of unit parts

1.Belt pulley

2.Heat exchanger water outlet

3.Heat exchanger water inlet

4.Intercooler water outlet

5.Intercooler water inlet

6.Fuel oil inlet (dewater safety

filter)

7.Fuel oil return opening

8.Fresh water filler

A． M20×1.5 (engine oil

discharge outlet)

C. Common base frame

D. Magnetic plug screw

E. Engine oil filter


- 6 -

1 Model In-line, four-stroke, water cooling, direct injection,

pressurization, intercooling

2 Number of cylinders 6

3 Cylinder diameter/stroke

mm/mm 126/165

4 Rotation of crankshaft

(towards the end of flywheel)Anticlockwise

5 Declared speed r/min 1500 1800

6 Declared power kW 288

7 Piston total displacement

L 12.54

8 Compression ratio 17:1

9 Start-up mode Electrical starting

10 Electric motor starting power

kW 5.4

11 Starting battery capacity

Ah Above 165

12 Starting cable mm2 70(mm2)

13 Fuel consumption under rated

conditions g/kW.h 200±5%

14 Fuel type Domestic 0# or -10# light diesel oil (GB252)

15 Fuel system Mechanical pump

16 Engine oil grade CF or above

17 Maximum oil volume of oil

pan L 23

18 Inlet air flow under rated

condition kg/h 1288 1376

19 Exhaust back pressure kPa ≤6

20 Exhaust flow under rated

conditions 1345 1433

21 Exhaust temperature before

turbine C ≤750

22 Exhaust temperature after

turbine C ≤550

23 (standard configuration) sea

water pump flow L/min 316

24 (standard configuration) sea

water pump lift 15


- 7 -

Note: this table mainly describes relevant parameters of WP12CD Series

1500r/min marine diesel engine. For this series, 1800r/min diesel engine can be used

for 250kW/60Hz and below gen-set if required by the customer.

II. AC Alternator

Alternator is a kind of equipment which is able to convert mechanical energy

into electric energy. Please refer to Alternator manual for detailed structure principles.

Main technical specifications are shown in Table 4-2:

Table 4-2 Main technical specifications

Serial

No. Item Value Remarks

1 Rated voltage V 400

2 Rated frequency 50

3 Rated power factor

cosφ 0.8 (legging)

4 Rated current A I=1.804P

5 Insulation grade F/H

6 Protection level IP23

7 Exciting mode Brushless self-excitation

8 Outgoing line Three-phase Y-connection

9 Bearing type Rolling bearing

10 Radio interference level Level N

11 Anti-condensation heater 220V

12 Stuffing box outlet direction In the left (seeing from diesel engine to

Alternator)

13 Steady-state short circuit

current 3-5times rated current, duration 5s

14 Over-current features 1.5 times rated current, last for 2 min

15 Cooling method Self-ventilation

III. Instrument box

Please refer to “Instrument box” in “Chapter VI Electric System of Gen-set” for

detailed structure functions.

IV. Solid base frame

The common chassisshall be made from bent steel plate.


- 8 -

Chapter V Storage and Installation

I. Storage

Storage yard shall be well ventilated with no acid gas, alkaline gas and other

corrosive gases and protected from the sun and rain. The factory guarantees that

gen-set can be stored for half a year after delivery, in case of more than half a year,

proper treatment measures shall be taken, such as Alternator winding insulation

measurement, moisture removal as the case may be.

II. Unpacking acceptance

Unpacking method: remove connections between packing case housing and the

bottom of packing case and use lifting tools to open the case. Note: a person shall be

assigned to support the packing case housing with hand during lifting to protect

exposed parts of gen-set from being damaged by packing case housing. Generally,

gen-set shall undergo unpacking acceptance after arriving in delivery destination.

Acceptance method and personnel shall be in accordance with contract specifications.

As the basis of acceptance, “packing list” shall be put in same document pocket with

other documents to be provided with the unit.

Basic acceptance items are:

Appearance inspection: check whether exposed parts are damaged by visual

inspection or whether there is collision, deformation and other abnormal phenomena

and make records;

Check accompanying documents according to the list of accompanying

documents and make records;

Check the spare parts according to the “list of accompanying spare parts” and

make records;

Check accompanying tools according to the “list of accompanying tools” and

make records.

In case that gen-set has any damages in appearance and accompanying spare

parts, attachment, documents and tools are inconsistent with the list. The

consigner and carrier shall be informed within 24 hours by fax or telephone

after acceptance for claims.

III. Lifting & handling

Steel wire rope shall have enough strength, and carrying capacity of lifting tools

shall meet safety specifications. Each steel wire rope shall be in the same length to


- 9 -

avoid tilting during lifting.

Steel wire rope shall be attached onto the lifting position of gen-set packing case

base.

When bare machine is lifted, steel wire rope shall be attached onto the lifting

position of the common chassisof the generating unit. Contact between steel wire rope

and other gen-set components shall be prohibited, if not, separate them with a board.

Cover lifting shall be stopped if contact parts are small or non-bearing parts, and try

again after changing the length of rope or adding support to change force bearing

point. Please contact us for any questions.

IV. Installation

1.Installationofgen‐setexternalpipes

Installation of various gen-set pipes shall abide by following rules:

External pipes and gen-set shall be connected by flexible hose.

Sharp turn shall be avoided on the pipe line, and bend & tee shall be avoided

in most cases.

For the convenience of maintenance, valves shall be installed in proper

position.

Pipes shall be reliably secured on the support. Measures should be taken to

relieve stress generated by expansion and contraction of pipelines.

After the completion of gen-set installation, oil supply and water supply can

only be allowed after pipes are totally cleaned. Test run shall be carried out

for checking whether various pipes meet relevant requirements, pipeline

pressure drop is too large, pump drive capability is enough and cooling water

flow meets operating requirements. Otherwise, pipes in larger size shall be

used.

2.Installationofvent‐pipe

(1) Installation of vent-pipe shall abide by following rules:

a. Vent-pipe dead-weight shall be reliably supported, and it is strictly prohibited

to use supercharger to bear vent-pipe weight. Generally, fixed support shall be located

1m away from expansion joint to prevent stress generated by vent-pipe gravity,

thermal expansion or transversal displacement from being transferred to supercharger.

Diesel supercharger shall be provided with precise bearing and impeller and has high

speed. In case that supercharger exhaust flange bears too much bending moment,


- 10 -

supercharger shaft will be deformed and normal operation of supercharger is disturbed

with noise which finally leads to the damage of supercharger.

b. External vent-pipe shall be made from steel tube without too many turns and

shall be fixed tightly on ship body with no vibrations. Its weight shall not be applied

on diesel expansion pipe. Exhaust back pressure of diesel engine shall be not greater

than 6kPa after the completion of exhaust system installation. Otherwise, diesel

engine performance will be affected. As diesel vent-pipe surface temperature is high

during operation, vent-pipe shall be kept away from flammable objects to avoid

worker scald. Thermal insulation apparatus shall be mounted on the surface of

external exhaust pipes.

c. Exhaust silencer shall be installed on the end of vent-pipe to reduce influence

of exhaust noise.

d. There is vapor generated in the process of diesel oil burning, therefore,

condensate water drain valve shall be installed on vent-pipe to discharge condensate

water in vent-pipe. Condensate water drain valve shall be located as low as possible

on the pipe close to diesel engine.

(2) Diffuser pipe and vent-pipe diameter

The size of the bellow expansion joint provided by the manufacturer is not

exactly the same as the diameter of vent-pipe. Sometimes, a 500-800mm long diffuser

pipe with increasing diameter is needed, which is also used as a connector to reduce

airflow resistance. Diffuser pipe can be made from 3-5mm sheet steel.

(3) Exhaust silencer

Exhaust noise is generated when diesel combustion emission is discharged from

exhaust valve to vent-pipe, which always causes exhaust gas vibration and pressure

wave. Pressure wave is the mixture of many waves of different lengths and

amplitudes. These wave lengths (frequency) and amplitudes (loudness) are all within

the recognizable range of human ear.

Exhaust silencer can consume and absorb the energy of pressure wave to reduce

pressure wave amplitude of exhaust gas discharged from exhaust silencer. Most diesel

exhaust silencer reduces acoustics energy by reflecting the pressure wave. Generally,

increase of silencer dimension will improve noise reduction effect. If there is

limitation on silencer dimension, increase of silencer decay degree will result in

increase of exhaust resistance. Therefore, proper silencer shall be selected according

to the resistance of exhaust system.


- 11 -

Exhaust silencer is not covered in standard supply scope. The user can purchase

in the market or order from us.

3.Installationoffuelpipes

Installation of fuel pipes shall abide by following rules:

a. Volume of fuel tank for everyday use can keep gen-set continuously running

for at least 8h.

b. Oil tank shall be made aluminum sheet, phosphatization steel plate, and

reinforced plastic plate instead of galvanized steel plate.

c. Contact between oil return pipe and high temperature components (such as

vent-pipe, turbocharger, exhaust gas return pipe) of diesel engine shall be avoided

during installation. Throttling area is not allowed in oil return pipe. Return pipe shall

not contact with sharp edges, be bended with sharp corners or distorted. Improper

installation of return pipe will lead to fuel leakage on Alternator. Fuel return pipe shall

be connected to fuel tank with returned oil flowing along with the tank wall to reduce

eddying flow. The return oil of WP12CD series diesel engine is internal return oil

passed through cylinder head (Figure 5-1). Oil injector mounting hole in cylinder

head can ensure that return oil can be fully sealed.

Figure 5-1 Oil return method

d. Diesel engine inlet and outlet fuel pipe shall be equipped with stop valve for

the convenience of maintenance.

4.Installationofcoolingpipes

Proper installation of cooling system plays an important part in diesel engine

service life and performance. Please read the operating principles and installation

Injector oil

return hole

O-ring sealing

oil return

Seal ring

Internal oil return through cylinder head


- 12 -

precautions of cooling system to ensure the design and installation of gen-set external

pipes meet following requirements:

(1) Diameter of inlet and outlet pipes shall meet relevant requirements of

gen-set. Large diameter pipes shall be used when too many lengthy pipelines are

required. Excessive resistance of pipeline system will lead to insufficient flow of

cooling water; therefore, the diesel engine is lack of sufficient cooling water which

causes abnormal operation of the diesel engine. Elbows and tees shall be minimized.

(2) Pump suction pipe shall be as short as possible to guarantee that pump water

inlet pressure is greater than atmospheric pressure (i.e. positive pressure). Negative

pressure will cause pump gas etching and insufficient cooling water flow which cause

abnormal operation of pump.

(3) Pipeline system must be equipped with exhaust apparatus to discharge air in

pipeline.

(4) Purchase a new pump when the lift of the pump supplied with the unit can

not satisfy pipeline lift requirement.

(5) Preservative must be added to cooling water in closed cooling system. Filter

screen shall be mounted on water suction pipe mouth in open type cooling system to

protect intercooler and oil/water cooler from being blocked by dirts.

Sea water inlet

Diesel engine intake

Sea water outlet

Intercooler Fresh water

pump

Diesel engine

Small circulation

Diesel engine effluent

Box-type fresh water heat exchanger

Fresh water filler

Thermostat


- 13 -

Figure 5-2 Circulating cooling system diagram

5．Installationofstartingsystem

Sectional area of cables (multi-core copper flexible cable) between starting engine

and the battery shall be not less than 70mm² and the length shall not exceed 1.5m. Our

standard marine diesel gen-sets are all equipped with starting battery cable.

6.Otherrequirements

a. A 1m maintenance space shall be reserved around gen-set.

b. Foundation of gen-set shall be firm and has no deformation during installation

and operation of gen-set. During installation, level gauge shall be used to measure the

levelness of foundation installation surface which should be leveled up with flat

gasket to ensure that the gen-set can be placed horizontally. Gen-set shall be fixed

with foundation bolt and its classis undersurface shall be in good contact with the

ground during installation, in case of gaps, use thin iron sheet to level them up to

guarantee the concentricity of diesel engine and Alternator axial lead.

c. Diesel vent-pipe shall extend outboard to facilitate ventilation, and vent-pipe

bending angle shall be not less than 90° without too many bends. Inner diameter of

external vent-pipe shall not be less that the inner diameter stipulated in Diesel Engine

Operation and Maintenance Manual. Vent-pipe shall not be too long and satisfy fire

protection requirements. Vent-pipe and the diesel engine shall be in flexible

connection instead of rigid coupling. Water drain valve shall be installed at the lowest

position of vent-pipe in order to guarantee the smooth discharge of condensate water

in vent-pipe. For other requirements, follow the Diesel Engine Operation and

Maintenance Manual.

d. The cabin shall be equipped with intake channel and exhaust channel. There

shall be no obstacles obviously hindering the airflow.

e. If ambient environment of gen-set in the winter is lower than 0C, anti-freezing

solution shall be added into gen-set cooling system.

f. Fuel tank separate from gen-set shall be 0.5m above the ground.

g. Sectional area of gen-set major loop connecting cable shall meet relevant

current requirements.

h. Gen-set must be equipped with ground lead and reliably grounded.

Chapter VI Gen-set electrical system


- 14 -

I. Instrument box

Please refer to Operation Manual for Diesel Engine Monitoring and Control

Instrument delivered with gen-set for main operation and maintenance instructions for

instrument box. Brief introduction to several common instrument boxes is hereunder

provided. We can also produce special instrument boxes according to customer’s

special requirements.

1.Localordinaryinstrumentbox

Local ordinary instrument box of WP12CD Series marine diesel gen-set is a

microcomputer-controlled full-automatic electronic measurement and control system

for the diesel engine and Alternator which precisely detects and displays diesel engine

speed, oil pressure, water temperature, oil temperature, pressure and other parameters,

and monitors all detected parameters to send out audible alarm, visual alarm, remote

alarm and other signals in real time. In addition, it is provided with starting and

stopping functions. So it will send out shutdown signal when the parameter exceeds

shutdown limit. Meanwhile, remote displayer or diesel engine remote display

instrument can also be used to realize remote monitoring and control of diesel

operating parameters. There are several indicators on instrument box which can

display the operating status and functional status of gen-set in real time. Instrument

box is characterized by advanced design, high measurement precision, reliable

operation, small size, digital display, precise and clear display, and easy installation.

Figure 6-1 Standard ordinary local instrument panel


- 15 -

6-1 Local ordinary instrument panel

(1) Operating function

Table 6-1 Local ordinary instrument function

Serial

No. Name Function description

1 Power switch Turn on this switch to power on the instrument box.

2 Local/remote

control Selection of diesel control position.

3 Starting Instrument box will send out signals to start the diesel engine by

pressing this button.

4 Idling/rated When the switch is in “rated” position, diesel engine runs in high speed;

When the switch is in “idling” position, diesel engine runs in low speed.

5 Shutdown Instrument box will send out shutdown signal to shutdown the diesel

engine forcefully by pressing this button.

6 Emergency

shutdown

When diesel engine shutdown and emergency shutdown functions are

used, this button has self-locking function. Press this button to close fuel

magnetic valve and shut down the diesel engine forcefully. Press this

button again after the diesel engine is completely stopped to open fuel

magnetic valve for next starting.

7 Speed fine

adjustment Diesel speed fine adjustment

8 Self-inspection Press this button when there is no rotation, various channels of


- 16 -

instrument box will simulate external changing conditions to carry out

self-inspection items one by one. Instrument box will send out audible

and visual alarm signal when alarm setting value is reached, and

instrument box will send out automatic stopping signal when stopping

setting value is reached.

9 Silencer Press this button when there is alarm signal, and the audible alarm will

be turned off and alarm light keeps shining and stop blinking.

10 Timekeeping Press this button, and speed display window shows the accumulative

running time of diesel engine. Speed will be displayed after 5 sec.

11 Reset Press this button to reset instrument box

Please refer to accompanying document Operation Manual for Diesel Engine

Monitoring and Control Instrument for more function descriptions and usage

information.

(2) Local ordinary instrument box alarm protection function

Table 6-2 Local ordinary instrument box alarm protection function

Serial



speed Audible and visual alarm

2 Oil pressure is low 0.12±

0.02Mpa Audible and visual alarm

3 Water temperature is

high 95+3C Audible and visual alarm

4 Oil temperature is

high 102+3C Audible and visual alarm


speed Audible and visual alarm and shutdown

6 Oil pressure is too

low 0.080.02Mpa Audible and visual alarm and shutdown

7 Battery voltage is low <19V Audible and visual alarm

8 Fuel leakage alarm

(optional)

Audible and visual alarm; fuel leakage alarm

apparatus is required

(3) Local ordinary instrument wiring diagram


- 17 -

Figure 6-2 a) Local ordinary instrument wiring diagram

Figure 6-2 b) Local ordinary instrument wiring diagram

2.Localself‐startinginstrumentbox

Local self-starting instrument box (hereinafter referred to as instrument box) of

WP12CD Series marine diesel gen-set is a microcomputer-controlled full-automatic

electronic measurement and control system. The whole system has functions of

Wiring diagram E

xcitation voltage

Onboard A

lternator

Pow

er supply-

Pow

er supply+

Starting m

otor

Rem

ote high/low speed control

Control position signal output

Diesel operation signal output

Com

prehensive alarm output

Fuel leakage alarm

input

Outage m

agnetic valve

Double output during

pneumatic starting

Rem

ote starting

Rem

ote emergency

Rem

ote shutdown

Shunt passive alarm contact, contact to central control

room

Microcomputer self-starting controller

Alarm when speed

is high

Relay board

Stop when water

temperature is high

Battery undervolta

ge

Alarm when oil

temperature is high

Alarm whenwater

temperature is high

Alarm when oil

pressure is low

Fuel leakage

Rated speed

Successfulstarting

Stop indication

Stop when oil pressure is low

Stop when speed is

high

Alarm when speed

is high

Stop when water

temperature is high

Battery undervolta

ge Alarm

when oil temperature is high

Alarm whenwater

temperature is high

Alarm when oil

pressure is low

Fuel leakage

Rated speed

Successfulstarting

Stop indication

Stop when oil pressure is low

Stop when speed is

high


- 18 -

distribution panel loss of power status monitoring, automatic starting of diesel engine,

automatic monitoring and measurement of working conditions, output of diesel

Alternator automatic switching on and tripping signals, automatic stop, limit

protection and other basic monitoring and control functions. Control of speed-up and

speed-down, preheating of cooling water and lubricating oil and electronic speed

regulating control can also be configured for the diesel engine on the basis of basic

functional configuration. Meanwhile, remote display or diesel remote display

instrument can also be configured to perform remote monitoring and control of diesel

operating parameters. There are various indicators on instrument box which displays

gen-set operating status and functional status in real time. In addition, many ways are

available for the communication between instrument box and cabin distribution panel

to realize remote control of the operation, remote monitoring and measurement,

remote RS485 communication so as to form a highly automatic marine diesel

generating station.

Figure 6-3 shows standard local self-starting instrument box operation panel

Figure 6-3 Self-starting instrument panel

(1) Operation function

Table 6-3 lists the operation functions of local self-starting instrument

Table 6-3 Operation functions of local self-starting instrument

Serial Name Function description


- 19 -

No.

1 Power switch Turn on this switch to power on the instrument box.

2

Manual/

automatic

switching

Local operation can be performed when the switch is in

“manual” position.

Gen-set is in standby status when the switch is in “automatic”

position to automatically supply power for startup or stop

power supply for shutdown according to instructions from

switch panel.

3 Starting Self-starting instrument box will send out signals to start the

diesel engine by pressing this button.

4 Idling/rated

When the switch is in “rated” position, diesel engine runs in

high speed;

When the switch is on “idling” position, diesel engine runs in

low speed.

5 Shutdown Press this button to stop the diesel engine forcefully.

6 Emergency

shutdown

Operator can manually shut down the diesel engine in

emergency cases by pressing this button. Actuator can be

controlled manually to cut down the fuel pipe by this button

so as to shut down the diesel engine and open the main switch

of gen-set forcefully.

7 Speed up/speed

down Diesel engine speed fine adjustment

8 Voltage fine

adjustment Alternator voltage fine adjustment

9 Heating switch

When gen-set is in standby status, open this switch and the

heater works after being charged. When diesel engine is

started or in operation, the heater will be automatically

switched off and stop work.

10 Self-inspection

Press this button when there is no rotation, self-starting

instrument box will simulate external changing conditions to

carry out self-inspection items one by one. Audible and visual

alarm signal will be sent out when alarm setting value is

reached and automatic stopping signal will be sent out when

stopping setting value is reached.

11 Silencer

Instrument box can send out audile and visual alarm signals

when diesel engine working condition is out of limit or the

diesel engine fails to start for three times, and relevant alarm


- 20 -

indicators on the panel twinkles; meanwhile digital display

window corresponding to digital displayer twinkles. Press

“Silencer” button, and audible alarm will be turned off and

alarm light keeps shining and stop blinking until the operation

returns to normal conditions.

12 Timekeeping

Press this button, and speed display window shows the

accumulative running time of diesel engine. Speed will be

displayed after 5 sec.

13 Reset

In case that diesel engine fails to start for three times and

stops because limit protection is triggered, it represents that

the diesel engine is faulty and needs to be repaired. In case

that gen-set is to be started after troubleshooting, press “reset”

button to notify the instrument box that the fault is

eliminated. At this time, controller will cancel alarm signal

and put gen-set into operation again.



information.

(2) Alarm protection function

Table 6-4 Self-starting instrument alarm function

Serial

No.

Alarm description Alarm value Remarks


speed

Audible and visual alarm


0.02Mpa



high

95+3C Audible and visual alarm


high

102+3C Audible and visual alarm


speed

Audible and visual alarm and shutdown


0.02Mpa

Audible and visual alarm and shutdown

7 Battery voltage is

low

＜19V Audible and visual alarm


- 21 -

8 Starting fails three

times



(optional)

Audible and visual alarm, and fuel leakage

alarm apparatus is required

(3) Local self-starting instrument box wiring diagram

Figure 6-4 a) local self-starting instrument box wiring diagram

Figure 6-4 b) local self-starting instrument box wiring diagram

Alarm when speed is high

Alarm when oil pressure is

low

Alarm when water

temperature is high

Alarm when oil

temperature is high

Battery

undervoltage

Fuel

leakage

Failure

starting

Microcomputer self-starting controller

Speed Oil pressure

Oil temperature

Water temperature

Oil

temperature

sensor

Speed sensor

Oil

pressure

sensor

Water temperature

sensor

Remote control 10-core aviation plug

Remote control 5-core aviation plug

Alarm

when speed

is high

Battery

undervoltage

Alarm when oil

temperature is high

Alarm when

water

temperature is

high

Alarm when oil

pressure is low

Fuel

leakage

Failure

starting

Alarm when oil

pressure is low

Relay board


- 22 -

Figure 6-4 c) local self-starting instrument box wiring diagram

3.Newstylelocalordinaryinstrumentbox

On the basis of original WP12CD marine diesel gen-set local ordinary

instrument panel, our company has launched new style local ordinary instrument box

by optimizing instrument box components and parts, its functions and redesigning

appearance. New instrument box has more beautiful appearance, firm installation,

reasonable functional design, beautiful wiring layout and convenient plug connectors.

Instrument box is a microcomputer-controlled full-automatic electronic measurement

and control system of diesel engine and gen-set which precisely detects and displays

diesel engine speed, oil pressure, water temperature, oil temperature, water pressure

and other parameters and monitors all detected parameters according to user’s settings

and sends out audible alarm, visual alarm, remote alarm and other signals. If there is a

stop setting, it will send out shutdown signal when the parameter exceeds shutdown

value. Meanwhile, remote displayer or diesel engine remote control display

instrument can also be provided to realize remote monitoring and control of diesel

engine operating parameters. There are several indicators on instrument box which

can display the operating status and functional status of gen-set in real time. Diesel

engine instrument box also has diesel engine running time accumulation function. It

can also provide extended alarms, diesel engine operating parameter and computer

data communication functions according to user’s special requirements.

Figure 6-5 standard new style ordinary local instrument panel


- 23 -

Figure 6-5 New style local ordinary instrument panel


Table 6-5 New style local ordinary instrument function

Serial


1 Power switch Turn on this switch to power on instrument box.

2 Local/ remote

control Selection of diesel engine control position.

3 Starting Instrument box will send out signals to start the diesel engine by


4 Idling/rated

When the switch is in “rated” position, diesel engine runs in high

speed;

When the switch is in “idling” position, diesel engine runs in low

speed.

5 Shutdown Instrument box will send out shutdown signal to shutdown the diesel


- 24 -

engine forcefully by pressing this button.

6 Emergency

shutdown

When diesel shutdown and emergency shutdown functions are used,

this button has self-locking function. Press this button to close fuel

magnetic valve and close the diesel engine forcefully. Press this button

again after the diesel is completely stopped to open fuel magnetic

valve for next starting.

7 Speed fine

adjustment Diesel speed fine adjustment

8 Self-inspection

Press this button when there is no rotation, various channels of

instrument box will simulate external changing conditions to carry out

self-inspection items one by one. Instrument box will send out audible

and visual alarm signal when alarm setting value is reached and

instrument box will send out automatic stopping signal when stopping




10 Timekeeping Press this button, and speed display window displays the diesel

accumulative running time. Speed will be displayed after 5 sec.

11 reset Press this button to reset the instrument box.



information.

(2)New style local ordinary instrument box alarm protection function

Table 6-6 new style local ordinary instrument alarm protection function

Serial

No. Alarm descriptions Alarm value Remarks


speed Audible and visual alarming

2 Oil pressure is low 0.12 ±

0.02Mpa Audible and visual alarming


high 95+3℃ Audible and visual alarming




speed Audible and visual alarming and shutdown


- 25 -

6 Oil pressure is too

low

0.08 ±

0.02Mpa Audible and visual alarming and shutdown

7 Storage battery

voltage is low <19V Audible and visual alarming

8 Water pressure is low 0.01MPa Audible and visual alarming


(optional)

Audible and visual alarm, and fuel leakage

alarm apparatus is required

10 Main power source

fails Audible and visual alarming

11 Auxiliary power

source fails Audible and visual alarming

(3) New style local ordinary instrument wiring diagram

Figure 6-6 a) New style local ordinary instrument wiring diagram


- 26 -

Figure 6-6 b) New style local ordinary instrument wiring diagram

4.Newstylelocalself‐startinginstrumentbox

On the basis of original WP12CD marine diesel gen-set local ordinary

instrument panel, our company has launched new style local ordinary instrument box

by optimizing instrument box components and parts, its functions and redesigning

appearance. New instrument box has more beautiful appearance, firm installation,

reasonable functional design, beautiful wiring layout and convenient plug connectors.

Marine diesel Alternator new style local self-starting instrument box (hereinafter

referred to as instrument box) is a full-automatic Alternator working condition

electronic monitoring and control system, which is controlled by a control system

consisting of GEC16W monitoring display module and GEC8000-K1 safety

protection module. GEC16W monitoring display module has a large LCD which has

CAN communication interface and displays Alternator speed, oil pressure, water

temperature, oil temperature and other parameters. Meanwhile, it can also detect

battery voltage, Alternator accumulative operating time and other parameters; monitor

and display all detected parameters in real time. When there is alarm signal detected

in control box, it will send out audible and visual alarm signals; when fault shutdown

signal is detected (for example over-speed shutdown), control box will output

shutdown control signal automatically to stop the Alternator. Control box system can

be used to perform automatic starting and automatic shutdown operations. Meanwhile,

remote displayer or diesel engine remote control display instrument can be used to


- 27 -

perform remote monitoring and control of diesel engine remote display instrument.

Figure 6-7 shows the new style local self-starting instrument box operation panel

Figure 6-7 new style local self-starting instrument panel


Table 6-7 shows the operation functions of new style local self-starting

instrument

Table 6-7 Operation functions of new style local self-starting instrument

Serial


1 Power switch Open this switch to power on the instrument.


- 28 -

2 Local/remote/automatic

control

Selection of “remote”, “local” and “automatic”

control mode

3 Heating switch

Alternator oil/water heater control switch. Such

change-over switch shall be in “off” position during

normal condition; change-over switch shall be in

“on” position when oil water heater indicator light is

on.

4 Idling/rated

When the switch is in “rated” position, diesel engine

runs in high speed;

When the switch is in “idling” position, diesel engine

runs in low speed.

5

Starting of standby

device

This button can be used for emergency start when

GEC 16W module fails.

6 Emergency shutdown

This button shall be used by operator for the

emergency stopping of diesel engine. Actuator is

manually controlled by using of this button for

disconnecting fuel pipe, stopping diesel engine and

open the main switch of gen-set forcefully.

7 Starting Used to control the starting of Alternator under local

mode.

8 Shutdown Used to control the stop of Alternator under local

mode.

9 Scrolling up/down

To change displayed content (parameters of

Alternator) on the main page, select parameter

number on the parameter selection page, and set the

digitals on the parameter editing page.

10 Page switching

To switch to parameter selection setting page from

the main page, return to the main page from

parameter selection setting page, and return to

parameter selection setting page under parameter

modification status.

11 Confirmation

To enter into corresponding submenu from parameter

selection setting page, and write the modified

parameter under parameter modification status.

12 Self-check in double

MODE combination

Press the two buttons when Alternator stops running,

and the system will enter self-check procedure and

displays user’s predefined Alternator parameters

successively, such as number of flywheel tooth, rated

speed, over-speed alarm value, etc. The system will

return to initial state automatically after completion


- 29 -

of self-check procedure.

13 Silencer

Instrument box can send out audile and visual alarm

signals when diesel engine working condition is out

of limit or the diesel engine fails to start for three

times, and relevant alarm indicators on the panel

twinkles; meanwhile digital display window

corresponding to digital displayer twinkles. Press

“Silencer” button, and audible alarm will be turned

off and alarm light keeps shining and stop blinking

until the operation returns to normal conditions.

14 Reset

In case that diesel engine fails to start for three times

and stops because limit protection is triggered, it

represents that the diesel engine is faulty and needs

to be repaired. In case that gen-set is to be started

after troubleshooting, press “reset” button to notify

the instrument box that the fault is eliminated. At this

time, controller will cancel alarm signal and put

gen-set into operation again.



information.

(2) Alarm protection function

Table 6-8 New style self-starting instrument alarm function

Serial



speed Audible and visual alarming


0.02Mpa Audible and visual alarming



4 Oil temperature is high 102+3℃ Audible and visual alarming


speed Audible and visual alarm and shutdown

6 Oil pressure is too low 0.08±

0.02Mpa Audible and visual alarming and shutdown

7 Storage battery voltage is <19V Audible and visual alarming


- 30 -

low

8 Starting fails for three

times Audible and visual alarming


(optional)

Audible and visual alarming, and fuel

leakage alarm apparatus is required

10 Water level/oil level is

low (optional)

Audible and visual alarm, and level switch

is required

(3) New style local self-starting instrument box wiring diagram

Figure 6-8 a）new style local self-starting instrument box wiring diagram

Figure 6-8 b) new style local self-starting instrument box wiring diagram

5.Onboardinstrument

Diesel engine monitoring and control instrument (hereinafter referred to as

monitoring and control instrument) shall be mounted on diesel engine body, so it is

called onboard instrument and is a microcomputer-controlled full-automatic electronic

measurement and control system of diesel engine and Alternator which precisely

detects and displays diesel engine speed, oil pressure, water temperature, oil


- 31 -

temperature, pressure and other parameters, monitors all detected parameters and

sends out audible alarm, visual alarm, remote control alarm and other signals in real

time according to user’s settings. If there is a stop setting, it will send out shutdown

signal when the parameter exceeds shutdown value. Meanwhile, remote displayer or

remote control display instrument can also be used to realize remote monitoring and

control of diesel engine operating parameters. Compared with local instrument,

onboard instrument is simpler in structures and functions.

Figure 6-9 onboard instrument panels

6-9 onboard instrument panel

(1) Operating function

Table 6-9 onboard instrument function

Serial


1 Power switch Turn on this switch to power on the onboard instrument.

2 Local/ remote

control

When “local/remote” control change-over switch is in “remote”

position, the monitoring and control instrument shall be in remote

control state; therefore, remote control instrument can be used to start

the diesel engine remotely. When “local/remote” change-over switch

is in “local” position, monitoring and control instrument shall be in

local status; therefore, the diesel engine can be controlled locally.


- 32 -

3 Starting Onboard instrument will send out signals to start the diesel engine by


4 Shutdown Onboard instrument will send out shutdown signal to shut down the

diesel engine forcefully by pressing this button.

5 Self-inspection

Press this button when there is no rotation, various channels of

onboard instrument will simulate external changing conditions to carry

out self-inspection items one by one. Onboard instrument will send out

audible and visual alarm signal when alarm setting value is reached

and instrument will send out automatic stopping signal when stopping




7 Timekeeping Press this button, speed display window displays the diesel

accumulative running time. Speed will be displayed after 5 sec.

8 Reset Press this button to reset onboard instrument.



information.

(2) Onboard instrument alarm protection function

Table 6-10 Onboard instrument alarm protection function

Serial


1 Speed is high 110% Rated speed Alarming

2 Oil pressure is low 0.12±0.02Mpa Alarming

3 Water temperature is high 95+3℃ Alarming

4 Oil temperature is high 102+3℃ Alarming

5 Speed is too high 115% rated speed Alarming and shutdown

6 Oil pressure is too low 0.08±0.02Mpa Alarming and shutdown

7 Storage battery voltage is

low <19V

Alarming

8 Fuel leakage alarm (optional)

Audible and visual alarming, and

fuel leakage alarm apparatus is

required

(3) Onboard instrument wiring diagram


- 33 -

Figure 6-10 Onboard instrument wiring diagram

6.Acceleratorservomechanism

A set of accelerator servo mechanism shall be equipped for mechanically regulated

marine diesel gen-set to control diesel engine speed. Generally, WP12CD Series

marine diesel gen-set adopts A-300B6 type servo mechanism. Hereinafter provide a

simple introduction of such servo mechanism.

(1) Main technical data

Voltage: DC 24V Power: 40W

(2) Motor wiring diagram

Power

supply-

Power

supply+

Battery

charging+

Alarm+

Shutdown+

Starting+

Excitation+

Shutdown-

Com

prehensive alarm

Fuel leakage

(input)

Fuel leakage

(input)


- 34 -

(3) Typical application wiring diagram (reference)

(4) Precautions

1）Hand wheel shall rotate in clockwise direction from left to right during

electric or manual operation.

2）Hand wheel shall be pulled back during manual operation and make spindle

nose turn right by 60.

3）Hand wheel shall be pulled back during electric operation and make spindle

High speed limit

switch

Low speed limit

switch

Notes: KMA1, KMA2, KMA3 adopts SchneiderCJX2-Z/25A auxiliary equipment Contact 2-open, 1-close A-300B3 type servo mechanism Buttons SA1, SA2, SA3 adopts LA18. Indicator AD11


- 35 -

nose turn left by 60.

Please refer to Operation Manual for Servo Mechanism for more information about

the operation of servo mechanism.

II. Alternator

1. WP12CD Series marine diesel gen-set adopts five kinds of Alternators:

Marathon Alternator, Stanford Alternator, Siemens Alternator, Kangfu Alternator

(formerly known as Sanbo Alternator) and Landian Alternator. WP12CD Series

marine diesel gen-set is mainly configured with above-mentioned five

Alternators. Please refer to relevant Alternator operation manual supplied with

the unit for relevant Alternator descriptions and wiring principles.

2.Special configuration for marine Alternator

Working environment of marine gen-set is very bad. Moisture on water surface,

salt fog on the sea, oil mist in the cabin and large day and night temperature difference

has a bad influence on Alternator insulating material. Therefore, following special

configurations are added to marine Alternator.

(1) Air filter

Some dust, oil mist can be removed by installing air filter on Alternator air inlet

to prevent moist air during shutdown.

(2) Anti-condensation heater

220V electric heater shall be mounted on the end of Alternator stator winding.

Electric heater shall heat Alternator winding to remove moist air and prevent water

condensation on the winding.

(3) Winding temperature sensor, alarm and protection

Alternator’s external circuit or improper operation will lead to the sharp rise of

winding temperature which will exceed the Alternator’s temperature rise limit. In

order to prevent motor winding damage, temperature sensor shall be embedded on

motor winding. Temperature sensors are divided into two kinds: one is PTC

thermistor, the other is PT100, which together with detection, alarm and trip circuit,

can provide protection for the Alternator.


- 36 -

Chapter VII Operation

I. Preparation

1.Clean the dust and other dirt on gen-set surface.

2.Check whether various fasteners and connectors are loose and various

revolving components are flexible.

3.Check whether all electrical connection parts are in good contact and correct

wiring.

4.Add corresponding fuel into fuel tank to remove the air left in fuel system

according to fuel specifications stipulated in Diesel Engine Operation and

Maintenance Manual.

5.Check whether diesel lubricating oil meets requirements according to

lubricating oil specifications stipulated in Diesel Engine Operation and

Maintenance Manual. In case of replenishment, lubricating oil in corresponding

grade shall be added.

6.Check whether the stored cooling water meets requirements.

7.Check whether battery voltage is within specified ranges (generally it is

23-28V)

8.Check the status of following switches:

(1) Gen-set power distribution system air isolation switch shall be in normal

tripping position;

(2) Starting switch shall be in off position;

(3) Electron speed regulator “rated/idling” switch shall be in idling position.

II. Commissioning

1.Gen-set starting

1）Press “start” button to start the gen-set (pay attention to readings of

various instruments)

2）Observe whether various parts are in normal operation (engine oil

pressure shall be greater than 0.15Mpa)


- 37 -

3) Gen-set shall be in idling status (generally 600-750 r/min), idling engine

heating shall last for 5-10 min;

2.Engine heating

The diesel engine shall operate for 5-10min in idling status after the starting of

gen-set meanwhile observing diesel oil pressure, oil temperature, cooling water

temperature and diesel operating conditions, in case of abnormalities, shut down the

unit for inspection.

3.Acceleration and voltage buildup

High/low speed switch of electronic speed regulator mounted on gen-set shall be

switched to high speed position when diesel engine speed reaches rated speed, the

diesel engine will accelerate the speed automatically. Regulate speed fine adjustment

potentiometer to make diesel engine speed reach rated speed; at this time, Alternator

voltage shall be built up.

Regulate voltage setting resistor to make it reach rated value; then turn the voltage

change-over switch mounted on onboard detection device to check whether

three-phase voltage is in balance, no current value is shown, and Alternator indicator

light turns on.

4.Test run

1)During normal operation of the unit, connect the load and observe

whether various parts are in reliable operation and indicating device is in

normal operation;

2)About 25% rated load shall be connected during test run, and check

whether various parameter indicators and whether any abnormal noise

arising from Alternators or diesel engine;

3)Load shall be added gradually under normal operation and the load for

first test run shall be not greater than 80% rated load.

4)Observe the water temperature, oil temperature, oil pressure and other

diesel engine parameters and voltage, current and other electrical

parameters.

5)Record various parameters during operation.


- 38 -

Notes: sharp increase and decrease of load shall be prohibited during initial

operation.

5.Shutdown

Reduce the load gradually, turn off main switch and open load disconnector. The

diesel engine will operate at the speed reduced to idling value for 2~5 min; then the

Alternator will be stopped and various switches shall be turned off to separate these

units. Then the commissioning is finished.

Chapter VIII Parallel operation

Parallel operation of gen-set can increase power supply reliability and stability,

in addition, number of parallel gen-sets shall be determined according to load level in

places subject to large load fluctuation for economic operation.

I. Conditions for parallel operation

Gen-set shall meet following conditions during parallel operation:

(1) Voltage of gen-set to be connected shall be the same as that of operating unit;

(2) Frequency of gen-set to be connected shall be the same as that of operating

unit;

(3) Phase position of gen-set to be connected shall be the same as that of

operating unit;

(4) Phase sequence of gen-set to be connected shall be the same as that of

operating unit;

II. Methods

Common parallel connection methods include light extinction method, light

rotation method and synchronizing device method. Currently, the most commonly

used method is synchronizing device method. And synchronizing device method can

be divided into quasi-synchronizing parallel method and automatic self synchronizing

parallel method. Hereinafter provide the introduction of quasi-synchronizing parallel

method.

On implementation model, quasi-synchronizing parallel operation is divided into

manual quasi-synchronizing parallel method and automatic quasi-synchronizing


- 39 -

parallel method. Hereinafter provide the introduction of manual quasi-synchronizing

parallel method.

Gen-set to be connected in parallel shall be involved in synchronizing operation

after meeting the four parallel conditions stipulated in this Chapter. Operating steps

are as follows:

(1) Check whether phase sequences of two parallel gen-sets are consistent with

each other before parallel operation and use phase sequence indicating device to

check Alternator stator winding leading-out terminal marks.

(2) Start the gen-set and adjust the speed and voltage of two gen-sets into rated

value, meanwhile, their phase sequences shall be consistent (the adjustment of

gen-set steady-state speed regulation factor and steady-state voltage regulation

factor shall be completed before delivery). One gen-set shall be switched on

firstly (it can operate without load or be used to supply power);

(3) Regulate regulating resistor of gen-set to be connected to make the voltage be

consistent with that of the already connected unit;

(4) Manual quasi-synchronizing operation: observe the rotation of synchronizing

indicating finger, then make corresponding regulation upon frequency of gen-set

to be connected until synchronizing indicating finger reaches synchronizing

balance line in clockwise rotation and send out switch-on order immediately to

make put gen-set into parallel operation. After parallel operation, regulate the

speed of one gen-set to achieve power sharing balance. All input signals of

combined type synchronoscope shall be turned off after parallel operation to take

the synchronoscope out of service.

III. Load transfer in parallel

Load transfer shall be done after units are put into parallel operation. There are

load transfer method, one is active load transfer between two gen-sets which is

achieved by regulating accelerator to change diesel engine oil supply. Active load

increases along with oil supply; the other is transfer of reactive load, which can be

accomplished by using regulating differential resistor and voltage regulation resistor

on regulation panel to regulate reactive power between two gen-sets.


- 40 -

IV． Disconnection of parallel gen-set

When load of two gen-sets in parallel operation is less than the 50% of rated load

and one unit needs to be disconnected, all the load (or most part) of the unit to be

disconnected shall be transferred to the other unit by adjusting speed before turning

off load switch to disconnect the unit.

Chapter IX Precautions

1.Personnel who are unfamiliar with gen-set operating specification are

prohibited to operate on the unit.

2.Gen-set output current shall not exceed the rated current stipulated on

Alternator nameplate. Please refer to power correction method stipulated in

diesel engine Operation Manual to correct gen-set output power when gen-set

working condition does not conform to working conditions stipulated in this

manual.

3.During initial operation, maximum power of the unit shall not exceed 90% of

rated power which help extend service life. When gen-set is started in emergency

status, initial load shall not exceed 50% of rated power.

4.Check water temperature, engine oil pressure changes regularly to meet

specifications stipulated in diesel engine operation and maintenance manual.

5.Check battery voltage regularly to ensure it is in good condition.

6.During operation of gen-set, pay attention to cooling water level in box cooler

and replenish if necessary.

7.Repair it in a timely manner in case that there is oil leakage, water leakage and

air leakage in various pipes.

8.Do not use silicon rectifier to replace battery

9.Water in cooling system shall be discharged or anti-freezing agent shall be

added when gen-set ambient temperature is low with possibility of freezing to

prevent frost crack of unit body and water drainage shall be done after the unit

has stopped for half an hour.

10.During operation of gen-set, loading process shall be stable to avoid gen-set


- 41 -

from being damaged by impact load.

11.Gen-set shall be in horizontal position during lifting.

12.As gen-set can be exposed in moisture air, salt mist, oil mist and mould

environment, the user shall start it up regularly to guarantee that gen-set is in

good working condition to prevent gen-set from being corroded or damaged.

13.Pay attention to keep gen-set clean and make it in good working conditions.

14.Gen-set is heavy equipment. For the sake of human body and equipment safety,

it shall be operated with care. Operation against rules and drunk operation are

prohibited.

15.In case that there are any failures and factory assistance is required, the user

should provide the detailed information for quick solution.

Chapter X Analysis of common faults and troubleshooting

1.Analysis of common faults

Table 10-1 Analysis of common faults

Fault phenomena Analysis of causes Troubleshooting methods

Cannot be started

Battery fault Check battery wiring, capacity and

voltage.

Fuel circuit is blocked. Check whether fuel oil circuit is blocked

and discharge air in fuel oil circuit.

Electronic speed regulator Check electronic speed regulator.

No voltage

Excitation circuit is open. Check the wiring of excitation circuit.

AC, DC transformation system

is damaged. Refer to Alternator Operation Manual.

Fuse is damaged. Replace fuse.

Alternator voltage

is unstable.

Excitation circuit is in bad

contact. Check the wiring of excitation circuit.

Rectifier diode has poor

performance. Replace diode.


- 42 -

Alternator speed is

unstable.

Electron speed regulator does

not work in optimum status

Refer to electronic speed regulator

Operation Manual.

2.See Operation Manual for Three-phase Synchronous Alternator for

synchronous Alternator fault and troubleshooting methods.

3.See Operation Manual for Diesel Engine Monitoring and Control Instrument

for gen-set instrument box fault troubleshooting methods.

4.See Operation Manual for Electronic Speed Regulator for electronic speed

regulator fault and troubleshooting methods.

Chapter XI Rules for Safe Operation

1.Operator shall be familiar with gen-set operations, operation method and

positions of all control mechanisms, manual valves and stop mechanism.

2.Open flame is forbidden in cabin with fuel oil and lubricating oil to avoid fire.

3.Proper fire fighting equipments shall be equipped in cabin or in nearby places.

4.Whole gen-set must be earthed reliably and meet applicable neutral earthing

requirements.

5.The equipment, barriers and dangerous goods not to be used for the unit shall

not be placed on the unit and the ground shall be dry and clean without oil

contamination.

6.As there are noises generated during gen-set operation, it is recommended that

worker in noise environment shall wear proper safety devices, such as ear

protector.

7.All power supply lines must be disconnected before any maintenance,

especially DC power supply circuit. Set a “during maintenance” warning plate

and assign another person to ensure the safety, especially for maintenance

performed in narrow area.

Chapter XII Servicing and Maintenance

1.Please read relevant chapters of this Operation Manual carefully before

maintenance and servicing.


- 43 -

2.Generally, gen-set shall be inspected once a week. Operate for a short time with

load (best of all) to confirm that gen-set is in good status; meanwhile make

records on relevant conditions and parameters.

3.Basic maintenance specifications are as follows:

（1）Check the conditions of air filter, fuel filter elements, clean them in time and

replace them if necessary.

（2）Check cooling water or anti-freezing solution and replenish it in time.

（3） Check whether there is lubricating oil, fuel and cooling water leakage.

（4） Check whether oil in pump body is within specified limit and replenish it in

time.

（5） Check the battery voltage and specific gravity of electrolyte.

（6） Check the conditions of various indicating devices and various switches on

instrument box.

（7） Check whether electric connection and mechanical joint is loose and fasten it if

necessary.

4.Routine inspection items

（1）Diesel maintenance

The purpose of correct maintenance is to guarantee the normal and reliable

operation of diesel engine and is an important step to extend diesel engine service life.

The user shall maintain the diesel engine regularly according to technical maintenance

items stipulated in this Chapter.

1）Maintenance frequency of WP12CD Series diesel engine

First inspection (P) after diesel engine runs for 30-50 hours

Level I maintenance (WD1) after diesel engine runs for each 250 hours

Level II maintenance (WD2) after diesel engine runs for each 500 hours

Level III (WD3) after diesel engine runs for each 1000 hours

Level IV (WD4) after diesel engine runs for each 4000 hours


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Note: Above-mentioned frequency shall be calculated assuming that the unit

operate for 1500 hours annually, in case that diesel engine working time annually does

not exceed 500 hours, diesel engine maintenance frequency shall be 0.5 times

above-mentioned maintenance frequency; in case that diesel working time annually

exceeds 1500 hours, the maintenance frequency shall be 1.5 times above-mentioned

frequency.

Note: Lubricating oil of CE grade or lower is not allowed for WP12CD Series diesel

engine. Replace oil filter element during oil replacement.

3）Operations to be done during diesel engine inspection and maintenance

Table 12-1 Operations during diesel engine maintenance

Item First

inspection

Routine

inspection WD1 WD2 WD3 WD4

Replace diesel engine oil ▲ ▲ ▲ ▲ ▲ ▲

Check whether water pump leaks. ▲ ▲ ▲ ▲ ▲

Replace oil filter ▲ When replacing Alternator oil

Check and regulate air valve gap. ▲ ▲ ▲ ▲ ▲

Replace fuel oil filter. ▲ ▲ ▲ ▲

Clean fuel oil pump coarse strainer. ▲ ▲ ▲ ▲

Check the capacity of cooling

liquid and replenish if necessary. ▲ ▲ ▲ ▲ ▲ ▲

Fasten cooling pipe clamp. ▲

Fasten air inlet pipe and flexible

pipe. ▲ ▲ ▲ ▲ ▲

Clean air filter element. ▲ ▲ ▲

Check and fasten triangle belt. ▲ ▲ ▲ ▲ ▲ ▲

Check fuel oil injection pump in

special workshop. ▲

Regulate idling speed. ▲

(2) Gen-set routine inspection items

Note: “1” in Table 12-2 represents inspection after operation for each 12 h or

once a week; “2” represents inspection after operation for each 100h or once a month;

“3” represents inspection after operation for each 200h or once a year.

Table 12-12 Inspection items during diesel engine-gen-set maintenance

Parts Inspection item Frequency

Starting Check battery electrolyte level. 1


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part Use hydrometer to check the charging status. 2

Clean battery terminals and oil it again. 3

Alternator

Use dry compressed air to purge the porthole and internals. 2

Replace bearing lubricating grease (if necessary). 3

Check whether inner coupling bolt is loose. 2

Check whether there is barrier in ventilation area. 1

Check the conditions of Alternator outgoing line insulation. 1

Check the working condition of air isolation switch. 3

Check whether Alternator terminals are loose. 1

Gen-set

Check and fasten all bolts and nuts. 3

Check the status of damper. 3

Clean whole gen-set. 3

Operate gen-set for 1h at 50% load (optimal condition) and record the

starting time of gen-set. 1

Annex I: List of Tools Delivered with Gen-set (Ex-factory Standard

Configuration)

Serial No. Name Parts name Quantity

1 615GJ01 Tool box

2 615GJ010100 Angle Adjusting Driver 1

3 615GJ010200 Anlasser Disassembling Wrench 1

4 615GJ010300 Feeler 1

5 XB-A Filter wrench 1

6 615GJ0101 1/2 Dr Extension 280mm 1

7 615GJ0102 1/2 Dr Extension 120mm 1

8 615GJ0103 1/2 Dr Power Ratchet Wrench 1

9 615GJ0104 1/2 Dr Socket Set (12mm) 1

10 615GJ0105 1/2 Dr Socket Set (13mm] 1






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18 615GJ0114 Combination wrench(12mm) 1











29 615GJ0126 1/2 Dr Speeder Wrench 1

30 615GJ0127 Hex Wrench (5mm) 1

31 615GJ0128 Inner hex wrench(6mm) 1



34 615GJ0132 Intenal Snap Ring Ptier 1

35 615GJ0133 External Snap Ring Ptier 1

36 615GJ0134 Magnetisn Probing Pen 1

37 615GJ0135 Oil Draim Plug Driver 1

Annex II: List of Spare Parts Delivered with Gen-set (Ex-factory Standard

Configuration)

Serial

No.

Part Number Name Quantity Remarks

1 61000070005 Screw oil filter 2


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2 612600080934 Fuel filter element 2

3 612600020654 Polyrib belt 1

4 P00000110167 WD615/618 Marine standard

equipped 1

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