vpower genset operations, service and maintenance manual

8/10/2019 VPOWER Genset Operations, Service and Maintenance Manual

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Generator set technical manual 1

VPOWER Engineering (Shen Zhen) Ltd.

VPOWER GENERATOR SET

Operation / Service /Maintenance Manual

2014 Edition

VPOWER GENERATION


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Table of Contents

Content

Chapter 1 Weekly maintenance and safety regulation..... 2

1 . Weekly maintenance work system. 2

2 . Weekly maintenance work. 2

3 . The normal working condition of the engine. 4

4 . The generator test running. 4

5 . Safety precautions and notices... 5

6 . Wrong activation. . 6

7 . Battery... 6

Chapter 2 Commonly operation.. ... 8

1 . Common Operation.. 8

2 . The generator control panel . 9

3 . control panel introduction..... 9

4 . The Generator Controller DSE8610 Introduction. 10

5 . The generator start and stop...... 17

Chapter 3 Daily maintenance..... 18

Chapter 4 Maintenance plan... 19

Chapter 5 Troubleshooting.. ... 20

Chapter 6 Connection documents of after-service. 22


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Chapter 1 Weekly Maintenance And Safety regulation

1 . Weekly maintenance work system:The following weekly maintenance work system is applicable for the running status of

generator in common condition, but if the engine works in bad condition( such as

dust flying upward, poor-ventilated environment), the maintenance period should

been shortened.

If around the engine engine, the generator should not been started.

2 . Weekly Maintain work

Preventative maintenance begines with day-to-day awareness of the condition of the

engine and its systems.Before starting the engine,check the oil and coolant

levels.Look for: Leaks

Loose or damaged parts

Worn or damaged belts

Any change in engine appearance

COOLING SYSTEM

-- The coolant level must be checked daily and more often.

-- The water level should be 2 below affusion mouth.

-- If exchange the cooling water, inspect the proportion of antifreeze supplied.-- Inspect all the cooling piping and collet whether water leakage (like abrasion)

-- If use heat-scattering water tank, make sure no substance block the heat-scattering

sheet.

-- If use the heat-exchanging device, make sure all vavles are in right position.

Fill the cooling system with coolant to the bottom of the fill neck in the radiator

fill or expansion tank.

CAUTION:

-- Any time a significant amount of coolant is added, the Diesel coolant Additive

concentration must be checked. If the concentration is low, engine damage will

result.

NOTE:

-- Some radiators have two fill necks, both of which must be filled when the cooling

system is drained.

Lubrication System

-- Inspect the oil level of the lubricating oil to make sure it is within regulated scale

standard.

-- Inspect the oil quality of the lubricating oil to make sure whether water or fuel


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mixing into.

-- Inspect the lubricating system to make sure whether leakage exist.

Fuel Oil System

-- Inspect whether the valve of the fuel pipe is open.

-- Inspect whether the fuel pipe leaks.

-- Inspect the oil level of the fuel box to make sure that fuel should been supplied

before it is exhausted.

-- The vehicle must be level when checking the oil level to make sure the

measurement is correct.

CAUTION:

Never oprate the engine with the oil level below the low mark or above the high

mark.Wait at least 5 minutes after shutting off the engine to check the oil. Thisallows time for the oil to drain to the oil pan.

-- Check the valve of the fuel oil pipeline to have to leak.

Air cleaner System

-- Inspect whether the air-cleaner device is clean and observe the indicator (if

with)when generator running.

-- Inspect the oil level of the oil tray of the wet air-cleaning device(if used).

-- Under extremely dirty conditions an air pre-cleaner can be used. Clean the

pre-cleaner jar and dry-type air cleaner dust pans daily or more often, as necessary,

depending on operating conditions.

The switch function of circuit.

-- Inspect whether all the terminal indicator lights of the switch system of

internal-combustion engine are ok.

-- Check the engine monitor system daily (push button to test) per the manufacturers

recommentation to verify proper operation.

Battery

-- Inspect whether the electricity bottle liquid is enough, and its proportion should be

higher than 1.265. CAUTION:

When using jumper cables to start the engine, make sure to connect the cables in

parallel:positive(+) to positive(+) and negative (-) to negative(-). When using an

external electrical source to start the engine, turn the disconnect switch to the OFF

position. Remove the key before attaching the jumper cables.

Belt

-- Inspect the intensity of the strap of cooling fan and the charger(if one strap is

found wore, the whole group should been changed)


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DANGER

The danger emblem indicates that if no close attention is paied to, it will cause

people injury and death, generation damage.

WANRNING

The warning emblem indicates that if no close attention is paied to, it will cause

serious people injury and death, generation damage.

CAUTION

The caution emblem indicates that if no close attention is paied to,it may cause

people injury or generation damage.

Remark :These emblems should been paied attention to during install,operation or

maintenance,but it does not mean danger.

These safety emblems should been pasted on the relative obvious position of the

generator group to remind the operators or maintenance technician of paying

attention to these potential danger. As to the explanation of these emblems,you can

refer to all the safety precautions in this manual to make sure whether you have

understood the meaning of these emblems like emblems loss or damage which

should been exchanged quickly.

6 . Wrong activation Warning

Wrong activation may cause injury or death.

When working around the generator, firstly should break the battery away from

cable( remove cathode then connect)

Make the generator switch at the position of OFF.when working around the

facilityjoined with fuel generation, should remove activation electricity bottle and

cable(remove before connecting) to make generator group impossible to work.

If the above measurement is not taken, the generator group may been automatically

switched or remote switch control activation.

7 . Battery

Warning

The electrolyte can cause serious injury or death.

-- It is necessary to wear protective glove and clothes because the electrolyte can

cause permanent hurt to eyes,can burn skin and ablate clothes.

Warning

-- Exploding can cause serious injury or death,the relay of the battery charger can


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cause sparking.

-- The battery should been installed at well-ventilated place, and far away from

flammable gas.The electrolyte of the battery can cause serious injury or death. the electrolyte can

cause permanent hurt to eyes,can burn skin and ablate clothes. So when working

around battery, should wear safety antiseptic glove. If electrolyte spatters to skin,

should rinse for 15 minutes with sufficient clean water. If electrolyte spatters to

eye, you should seek the first-aid kit for medicining. The battery cant be appened

vitriol or it may cause the electrolyte metamorphosing.

Exploding will cause serious hurt or death, the gas liberated by the battery may

cause exploding, so around the battery smoking is prohibited and blaze or sparkle

generation is prohibited. Especially when the battery is charging, you should avoid

touching the terminal with tools, avoil exploding caused by sparkle. Before you

move the battery, you should turn off the watch, finger ring and other bullion

ornements. Do not connecte the anode and the cathode of the activation generation

shortly. Do not tset the capacity of the electric-bottle in the way of short, the

sparkle may emblaze the gas liberated by the battery or steam of fuel oil. The case

contained battery should be put in the breezy place to avoid explosive

gathering. Do not pull out the electric tie-in when charging to avoid sparkle

generation.Before pulling out the electric tie-in, you should turn off the power of

the charger first.The cathode of the power should be dismantled first and

connected last.

-- Removal: Disconnect the (-) negative battery cable first, then disconnect the (+)

positive cable.

-- Connect: Connect the (+) positive battery cable first, then connect the (-) negative

cable.


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Chapter 2 Common Operation1. Common Operation

Before starting the generator set, check for the following procedures. (Specialmaintenance procedures refer to CUMMINS Operation and maintenance

Manual)

Fuel oil system

-- Check the oil level,The vehicle must be level when checking the oil level to make

sure the measurement is correct.

-- Operate the engine with the oil level between the low mark and the high mark.

Cooling sytem

-- The coolant level must be correct.

--Fill the cooling system with coolant to the bottom of the fill neck in the raiator fill

or expansion tank.

--Some radiators have two fill necks, both of which must be filled when the cooling

system is drained.

--

Any time a significant amount of coolant is added, the diesel coolant additive

concentration must be checked. If the concentration is low, engine damage will

result.

--Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow

the engine to cool to below 50 before adding coolant.

Air cleaner:

--Clean the air cleaner jar and pans daily or more often, as necessary, depending on

operating conditions.

Other

--Check the oil pressure indicators, temperature indicators, warning lights and other

gauges to make sure they are operational.

--Check the engine monitor system (push button to test) per the manufacturers

recommendation to verify proper.


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-- VPOWER-- Operation Manual --

9

2 . The generator control panelNote: panel electric elements arrangement may not agree with actual, please use the actualarrangement shall prevail.

3. V500G CONTROL PANEL INTRODUCTION

ymbol term Function and Operation

W1 Genset ControllerDSE 8610

The DSE8610 is an Automatic Engine ControlModule,designed to provide advanced load share functionality fordiesel and gas generating sets that include nonelectronicand electronic engines. The module also providesexcellent engine monitoring and protection features.

The modules load share functions include, automaticsynchronizing with built in synchroscope and closingonto dead bus. Direct and flexible outputs from the

module are provided to allow connection to the mostcommonly used speed governors and automatic voltageregulators (AVRs).


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The module has been designed to combine a maximumof 16 generators and 16mains (utility) supplies up to amaximum of 20 in one system, e.g. 16 generators and4mains (utility) supplies (DSE8610 required tosynchronise with the mains).

The module has the ability to monitor under/over

generator volts, over current, under/over generatorfrequency, under speed, over speed, charge fail,emergencystop, low oil pressure, high engine temperature, fail tostart, low/highDC battery volts, fail to stop, generatorshort circuit protection, reverse power, generator phaserotation error, earth fault protection, loss of speed signal,fail to open, fail to close, out of sync,MPU open circuitfailure, negative phasesequence and loss of excitation.

W2 EM133 The EM133 is a smart DIN Rail Tou Energy Meter. TheEM133 can serve any application from residential energymetering,through industrial emergy and harmonicanalysis through utility comprehensive substationautomation.

PB1 Emergency StopButton

When the Generator is abnormal, press the Emergencystop button would stop the Generator immediately.

L Fault Light When the generator set occurred the fault, Light is on.

B1 Buzzer When the generator set occurred the fault, Buzzer is on,Warning the worker to check the Generator, and removethe fault.

A Charging Meter For battery charging meterSW1 Power Select

Switch(OFF/ON)Turn to ON position, Open the Controller of DSE8610,Turn to OFF position, Close the Controller ofDSE8610

SW2 Charging Switch Charging selector switch For battery charging (off / on)

SW3 Freq. Select Switch This selection switch can change the Generator offrequency&voltage(50Hz-400V/60Hz-380V/60Hz-480V)

SW4 Volt Trimmer(50Hz/400V)

This knob can change the magnitude ofvoltage(50Hz/400V)





4 . The Generator Controller DSE Model 8610 Introduction


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4.1 ICON DESCRIPTIONS


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4.2.2 AUTOMATIC MODE OF OPERATION

Automatic mode is used to start the set in response to an external start requirement from another

device. A number of options exist for the remote start input (selectable using 5xxx configuration

software).

Remote Start on Load input indicates to the controller that it should start the set, and run off load.

Remote Start on Load input indicates to the controller that it should start the set, synchronise (if

required) and share load with any other sets in the system.

Remote Start on Load Demand input indicates to the controller that it should start the sets,

synchronise (if required) and share load with any other sets in the system, automatically starting and

stopping sets on changing load demand.

This mode is activated by pressing the pushbutton. An LED indicator beside the button will

illuminate to confirm this operation.

Should the remote start input (if configured) become active then the following sequence is observed.

To allow for short term or false remote start signals, the Start Delay timer is initiated. After this delay,

if the pre-heat output option is selected then the pre-heat timer is initiated and the corresponding

auxiliary output (if configured) will energise.

After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then

one second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for CAN Bus, compatible ECUs willreceive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. PartNo. 057- 004 for more information on utilis ing DSE modules with electronicallycontrolled engines.

The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then

the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the

NOTE: - If a digital input configured to panel lock is active, changing module modes will

not be possible. Viewing the instruments and i is NOT affected by panel lock. If

panel lock is active the Panel lock indicator (if conf igured) illuminates.

NOTE:- If the Remote Start signal is removed during the Start Delay timer, the uni t wil l


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set number of attempts, the start sequence will be terminated and Fail to Start fault will be displayed.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency

measured from the alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing

can be used for speed detection (This is selected by PC using the 5xxx series configuration software).

Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for

underspeed or overspeed detection.

NOTE:-A load transfer wil l not be initiated until the Oil Pressure has risen. Thisprevents excessive wear on the engine.

After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High

Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise

without triggering the fault.

If the system has been started by a remote start off load input, the set will run off load.

Otherwise, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise. After the

Warm-up timer has expired then the module will close the load switching device.

In the case of a single generator system, the Generator Contactor/Breaker will be instructed to

close. The generator will then supply the requirements of the load.

On a multi-set system, if the common generator bus is live, the 8610 module will first synchronise

the generator to the bus before closing the Generator Contactor/Breaker.

A token is held by the module that first closed onto the dead bus and as only one token exists for

each multi-set system, this prevents other sets in the system from attempting to close their own

breakers.

For added security, the modules also monitor the bus. If this is found to be live, then the

synchronisation process begins.

Once the load switching device is closed, the 8610 will then ramp to share the load with the other

generators in the system.

NOTE:-A load transfer wil l not be initiated until the Oil Pressure has risen. Thisprevents excessive wear on the engine.

When the Remote start signal is removed, the Stop delay timer is initiated. Once this has expired,

the module will ramp the load from the generator to remaining set (Multi-set systems only). The

Generator Contact/Breaker will open and the Cooling timer is then initiated, allowing the engine a

cooling down period off load before shutting down. Once the Cooling timer expires, the FuelSolenoid

is de-energised, bringing the generator to a stop.


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For full details of multi-set operation please refer to the manual The Guide to sync and load share

Pt1

Should the Remote Start signal be re-activated during the cooling down period, the set will return on

load.

NOTE:- When synchronising is enabled, the bus is checked before closing anyload switch ing device. If the bus is live, synchronis ing wi ll take place before any closuretakes place.

- Synchronis ing can be disabled if the application does not require this funct ion.Contact your genset supplier in the first instance for further details.- The internal Scheduler can be configured to operate the system in the same manneras described for the Remote start input. Please refer to the 5xxx Configuration Softwaremanuals for full details on the feature.

4.2.3 MANUAL C MODE OF OPERATION

Manual mode is used to allow the operator to control the operation of the generator, and to

provide fault finding and diagnostic testing of the various operations normally performed during

Automatic mode operation.

MANUAL, mode is selected by pressing the pushbutton. An LED besides the button will illuminate to

confirm this operation. When the START ( I) button is operated, the module will initiate the start

sequence.

NOTE: - There is no Start Delay in this mode of operation.

If the pre-heat output option has been selected, this timer will be initiated and the auxiliary output

selected energised.

After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one

second later, the Starter Motor is engaged.

The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then

the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the

set number of attempts, the start sequence will be terminated and Fail to Start will be displayed.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency

measured from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing

can be used for speed detection (This is selected by PC using the 5xxx series configuration software).

Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used forunderspeed or overspeed detection.

After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,

NOTE:- If the unit has been configured for CAN Bus, compatible ECUs will receive

the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for more information on uti lising DSE modules with electronically contro lledengines.


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High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to

stabilise without triggering the fault.

Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to

stabilise before it can be loaded. Once the warm up timer has expired the generator is then

available to go on load and the Generator Available LED will illuminate on the front panel.

The generator will run off load unless:

1. A Remote Start on load signal is applied

2. An on-load run is configured in the scheduler.

3. The Close Generator button is pressed.

On a multi-set system, if the common generator bus is live, the 8610 module will first synchronise

the generator to the bus before closing the Generator Contactor/Breaker to close.

A token is held by the module that first closed onto the dead bus and as only one token exists,

this prevents other sets in the system from attempting to close their own breakers.

For added security, the modules also monitor the bus. If this is found to be live, then the

synchronisation process begins.

During the parallel run the module can be configured to either run at a fixed level output, such as

when used in parallel with an infinite bus. Alternatively, it can be configured to load share with

other generators on the bus. For full details of these mode please refer to the manual The Guide

to sync and load share Pt1

If the Open Generator button is pressed while in parallel, the module will ramp the load on the

remaining generators and then open the generator contactor/breaker.

If the Open Generator button is pressed and the generator is connected to the common generator

bus then the load is ramped off the generator and the contactor/breaker is opened.

IfAuto mode is selected and the remote start on load signal not active, and the scheduler is not

calling for a run, then the Return Delay Timer will start.

Once this has expired then the module will exit parallel operation and will ramp the load back to the

remaining generators. It will then open the Generator Contactor /Breaker. The generator will then run

off load allowing the engine a cooling period.

Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.

Detail data pls refer to DSE8610AUTOSTART CONTROL MODULEOPERATING MANUAL

5 . The generator start/stop

WARNING: - Operation of the STOP button in any mode will stop the generator operationand return the load switching sys tem to a safe state. This operation may lead to loss ofsupply to the load. It i s recommended that the STOP button is only operated once thegenerator is OFF LOAD and the mains supply provides power to the load.

- Synchronis ing can be disabled if the application does not require this funct ion.Contact your genset supplier in the first instance for further details.

- When synchronis ing is enabled, the bus is checked before closing any load witchingdevice. If the bus is li ve, synchronising will take place before any closure takes place.:- Upon closing the load switch ing device, the module checks that the bus becomes live.If it does not, an alarm is generated to indicate the problem.


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5.1 Manual Start

Turn the select switch SW1 on the ON position and set the controller to MANUAL

mode( ). Then press the Start button( ),The generator will running,observed the

volt and RPM, They are normal , then press the load switch( ), The generator will

with load output.

5.2 Auto Start

Turn the select switch on the ON position anf the set the controller to AUTO

mode, Genset will start automatically when there is a main failure.

5.3 The generator stop

5.3.1 Manual stop

Press down the controller stop button. The generator will stop.

5.3.2 Auto stop

While the controller is in AUTO mode. Genset will main comes back to normal.

5.4. . The generator paralleling

5.4.1 Manual paralleling:

Turn the select switch SW1 on the ON position and set the controller to MANUAL

mode( ). Then press the Start button( ),The generator will running,observed

the volt and RPM, They are normal , then press the button ( ), The controller of the

generator will automatically monitor the volt, RPM, phase angle on the MAINS, and

auto close the Gen ACB.

5.4.2 Auto paralleling:

Turn the select switch SW1 on the ON position and set the controller to Auto

mode( ).The genset will running when it received the remote starting signal.

The controller of the generator will automatically monitor the volt, RPM, phase angle

on the MAINS, and auto close the Gen ACB.


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Chapter 4 Maintenance plan

1FUEL FILTER PRIME GENSET: Every 250~1000 hours replaced the fuel filter

STAND BY GENSET: Half a year replaced the fuel filter

---TYPE: FS1006

QUANTITY`: 2entries

2OIL FILTER PRIME GENSET: Every 250~1000 hours replaced the oil filter

STAND BY GENSET: Half a year replaced the oil filter---TYPE : LF3325QUQNTITY :

5entries

3WATER FILTER PRIME GENSET: Every 250 hours replaced the water filterSTAND

BY GENSET: Half a year replaced the oil filter---TYPE : WF2076QUANTITY :

2entries

4BY PASS OIL FILTER PRIME GENSET: Every 250 hours replaced the by pass oil

filterSTAND BY GENSET: Half a year replaced the by pass oil filter---TYPE : LF777

QUANTITY : 2entries

5AIR FILTER PRIME GENSET: Every 400 hours replaced the air filterSTAND BY

GENSET: one year replaced the air filter, Also according to the filter indicator to replaced.

---TYPE : AH1135QUANTITY : 2entries

6MIXING TANK WATER Check water level day to dayHalf a year replaced thecoolant water

7REMOTE TANK WATER Check water level day to dayHalf a year replaced the

coolant water

8DAILY OIL TANK Check the oil level daily, added fuel oil in time.

9LUBRICATION OIL Replacement of half a year.

10

THE GENERATOR SET IN A SMALL MAINTENANCE

Please refer to EngineOpration and Maintenance Manual.

11THE GENERATOR SET IN A HEAVY MAINTENANCEPlease refer to Engine

Opration and Maintenance Manual.


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Chapter 5 Troubleshooting

Fllow the suggestions below for troubleshooting:

Study the problem thoroughly.

Refer to the engine system diagrams.

Do the easiest and most logical things first.

Find and correct the cause of the problem.

Troubleshooting table

FAILURE CAUSE CORRECTIONS

Battery voltage too low or bad; Charge or replace;

Battery connection broken, loose or corroded Check battery connections;

Controler fuse bad; Replace the fuse;

Emergency button have no reset Check and reset;

Failure to shut off; Check,removed the failure and reset;

Engine cant

start

Engine switch in OFF position Select switch to START position.

Fuel pump manual override open; Check to make sure manual override

screw is out to maximum travel;

Fuel pump shut-off valve disc stuck; Check opening and closing of

electrics;

Fuel tankvents plugged; Remove,clean,or replace vents;

Fuel drain lin restricted; Check fuel drain line for loops,

crimps, or clamped points;

Engine will not

shut off

Engine running on fumes drawn into air

intake.

Locate and isolate the source of

fumes.

Over current switch placed in OFF

position;

Select to ON position;No AC export

Engine failure Contact the service.

Oil pressure too low to shut down; Check the lubrication level;

Engine temp too high to shut down; Check the air cleaner and fan belts

Engine will

shut down

Coolant level too low to shut down; Check the coolant level.

Engine cranking speed low; Check engine cranking RPM;

Engine driven units engaged; Disengage engine driven units;

Cold start aid needed or not working

correctly;

Install cold start aid. Check, repair, or

replace if necessary.

Fuel filter plugged; Replace fuel filter;

Air in the fuel system Check for air in fuel, tighten fuel

connections and and filter, check fuel

tank stand pipe;

Engine hard to

start or will not

start

Fuel suction line restricted; Check fuel line for restrictions;


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Chapter 6 Connection Documents of after-service

VPOWER Engineering (Guang Zhou) Ltd.

Room 2107, 21/F, Newpoly Tower, No.2 ZhongShan 6 road,Yuexiu District, GuangZhou,China.

Post510180

Tel208326 6748

Fax208326 6948

VPOWER Engineering (ShenZhen) Ltd.

Building B7,North Yan Chuan Industrial Park,Songgang Town,Bao

An,Shenzhen,Guangdong Province,PR China.

Post518105

Tel7552706 4703-4

Fax7552706 5135

VPOWER Holdings Ltd.

Unit 3801B, Level 38, Tower 2, Metroplaza, No. 223 Hing Fong Road, Kwai Chung,Hong Kong.

Tel08522687 6517

Fax08522687 6854

E-mail : [email protected]

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