Diesel Generating Set Operation Guide By Saker Power Systems LebanonSdarPover System Introduction ‘This manual provides an operational guide for the Sakr Power Systom MANUAL generating sets, The pupose is to provide the necessary information and instructions for | the proper use of the genset, and to have a proper reliable power source. ‘This enst icp yen atinopantes danced eps conet which | are backed by along tne afer aque! poate ‘The generator and its control system are manufactured under a registered quality control system. With proper use according ta this manual it will give you the capability of being ready to respond to your emergency, stand by, or prime power needs, in this way it’s possible to guarantee a long life ofthe set under regular maintenance and safe operation, mowSection One i 12 13 14 1s 16 17 18 19 110 uu 12 113 114 Lis 116 uy Section two 21 22 23 24 25 26 27 28 ‘Table of contents General description of equipment Introduction... oe Description of the genset package. Engine. Air filtration, Governing system Cooling system, Feel system, Exhaust system, Antivibration system, Starting system, Labricating system Alternator, Voltage regulator Control system power supplies. Main circuit breaker. Control panel Control module. Safety Safety precautions. Pressure release of radiator Fire and explosion. Rotating parts Hot surfaces. = ‘Toxic and iritajing substances Electric shock. Lifting, Section three Installation Base and foundation Cooling and ventilation Exhaust system: ‘The fuel system: u n B u Sak Power Spt, , Section four 44 Maintenance Introduction. Routine maintenance Maintenance program 4.3.1 Daily maintenance. 43.2. Weekly maintenance 43.3 Monthly maintenance 43.4 Yeadly maintenance. ears | Section five | Section six ‘ 6.1 Maintenance program in ARABIC ly iceme eet aes a oe ———— 73 Control card (DSE 501-24Y).. ... eee 2B 25 26 26 ‘Saks Poner Syat [oe ae eo ou wowSakrPower Syate 1-General description of equipment L1 Introduction ‘Your new SAKR POWER SYSTEMS genset isa complete system thal incorporates advanced engineering concepts, which are backed by a long time of experience, ‘The gonsot is designed to provide you with superior performance and would not prevent you from geting the job done. Capability of being ready to respond to your emergency standby or prime power needs, alternator that produces the corect voltage with optimum wave form, fast response and precise voltage regulation are all available in your genset 1.2 Description of the genset package The genset major equipment ace al shown clearly inthe following figures (Lef, and ‘ight views) each with its key identification explained. The fll technical details of each part of equipment are within their manufacturer manuals included with this manual 1 2 a4 567 Pew unssirrover St | 1. Radiator. 2.Muffler, 3.Flexble 4, Exhaust outlet 5. Airfiter 6. Altemator. 7. Control Panel, 8. AirFan’ 9, Charging Dynamo. 10.AV.M 11. Oi1Fitters. 12, Oil | Precooler 13.BaseFrame. 14.Control Panel, 15.Main Cirouit Breaker 16.0 Sump 17 Starter. 18.AirFilter 19. Air Inlet, 20, Fuel Pump. 21. Starting Batteries, 22, Belts) “The engine incorporated in the genset is elisble and specifically designed in conjunctor | swith the genset allemator, The engines heavy-duty indatial pe ‘The cngine is presented with all acessories necessary to provide reliable power supply and sensors mounted that provide the contol panel wih the ol pressure, water J temperature, andthe baltery charging cuent ‘Also the Yosinial code andthe stil miner are stamped on an ENGINE, } IDENTIFICATION DATA PLATE postoned onthe engin. 1.4 Air filtration ] “The air filtering system consist of the following pats: ! 1. ‘The Cartridge Container j 2. the Cartridge 3. The Hose Line From Cleaner to the Air Inlet. | 4, ‘The Cleaner Status Gauge d J 1.5 Governing system "The governor primary function isto maintain the engine speed constant against load ‘variations. This is accomplished through an electronie governor 1.6 Cooling system The engine cooling system comprises a radiator, high capacity pusher fan, high wate temperature switch sensor, and water pump to provide water circulation from ts radito.} to the engine through a thermostat ) wewSal Pune Spe 1.7 Buel system Consisting ofthe main following elements: the pre-cleaner element, feedpump, primary ‘and secondary fuel filters with replaceble cartridges, main distribution pumps, injectors, supply and retum lines, anda daily fuel tank 1.8 Exhaust system Exhaust system is provided to reduce noise and to direct exhaust gases. It consists ofthe, flexible line and the silencer. WIS 1.9 Antivibration mounting Vibration isolators are designed to reduce the vibration produced by the engine and alternator mass. They were selected suitable for their particular duly and are fitted between the engine, alternator feet and the baseframe, 1.10 Starting system Starting system, which is presented by the cranking motor (starter) that was selected to produce sufficient torque to crank the engine. The cranking signal is confirmed by the control panel. 1.11 Lubricating system Lubricating system purpose is o lubricate moving parts, providing internal cooling and to keep the engine clean, Its main parts are: oil pump, ol high pressure relief valve, oil return to pan, ol pressure regulator assembly, full flow filter, bypass filter, and the accessory drive, 1.12 Alternator ‘The alternator is fan ventilated, sereen protected, drip proof, sel-excited, and self ‘regulating brushes types, with a winding inswlation An Automatic Voltage Regulator protective circ ‘control system ‘within the alternator performs theBow oOo esoe aa Beenie SikrPonee Sys 2Safety 2.1 Safety precautions ‘The genset contains necessary electrical and mechanical protections for the safety of the persons who install, use, and maintain it However, the responsibility for safe operation rests on two major points Verifying that all necessary protections are in good coalition, “Following the safety precautions For that, the genset should be operated by a trained person, which have read and understand the safety precautions. The ignorance of some of these safety precautions will increase the possibilty of accidents and injuries forthe operator and the persons who are nearby, 2.2 Pressure release of radiator {IF you want to check the coolant level inthe radiator, or add water to it, never remove the radiator cap while the engine is hot, Wait until the temperature is below 50°C before removing the pressure cap. Failure to do so will result in personal injury fom heated coolant spray or steam, 2.3 Fire and explosion To prevent fire, itis important to keep flammable liguid such as fuel and oil away froin hot surfaces. Several requirements should be done Clean up spills of fuel, cil, battery electrolyte, or coolant when it occurs. ~Smoking is prohibited when adding. fel, ol, or battery electrolyte. Yur off the battery charger before breaking the connections tothe battery Ant disconnect the ground connection prior the positive one, -Keep electrical wiring in good condition, and terminals clean and tight Do not operate the genset with any known leaks in the fuel system, Replace damages in ‘the fuel tank or lnes immediatly -Keep a fully charged COs ire extinguisher n extinguisher by the genset. Never use a water type fire2.4 Rotating parts “Keep hands, feet long hit, and also clothing away from belts and other moving parts, “Do not operate the genset with the rotating parts guards removed 1 “Shut off the engine before adding fuel, oil, coolant, or batery electrolyte. “possible, make adjustments when the engine is off hen stat it up to verify the results of the adjustments | “Keep hands, fee, floor, and walking surfaces clean and free of fuel, oil, and any other Tiquid to minimize the possibilty of slips and falls 2.5 Hot surfaces } -Avoid body contact with hot oil, hot coolant, and hot surfaces especially from the exhat pipes. ' Tprovide the personal with protective equipment such as gloves and head covering when) ‘working in or around the geaset 5 “Keep a first aid kit handy nearby and do not ignore small cuts.and bums because they ‘ay lead to infection. 2.6 Toxic and irritating substances J Operate the genset in open or well ventilated areas. “Discharge the exhaust fumes outside the plant room, and make sure that fumes recirculation does not occur ) “Care should be taken to avoid accidental ingestion or with fuel, ol, cootant, and battery electrolyte. Also avoid skin contact with battery acid, otherwise wash the skin immediat®l swith Iarge quantities of water and soap. 1] 2.7 Electrical shock Remove any metal or god gadget from your body before working with electri. To not contact any clectrical pats that could be energized unless supplying power is eu! “Do not work with genset while standing on a wet ground , “stop the engine, isolate the battery charger, disconnect the battery cables, au un vss jf ‘the circuit breakers before making electrical connections at the genset. “Keep all parts ofthe body, hand tools, and other conductive objects away wom hive pb in the genset electrical system, J “Close and lock al the access doors off the electric panelsmo ao es Eo oToDoO eee ee Suir Fover Sy 2.8 Lifting ‘The engine, altemator, and base fame ar provided with iting pints. When lifting the {gonset to transport it, several points shouldbe taken in consideration: Inspect the entire lifing points, ropes, and supporting structure for any damages, and ‘make sure they are in good condition (lift atleast the weight ofthe penset. -Use guide ropes to prevent twisting or swinging ofthe genset once itis lifted. Do not lift in high winds Keep the personnel away fiom under the genset once itis suspended, Place the genset down only on level surfaces capable of holding its weight, ~Keep the operator in constant attendance whenever the genset is suspended] 1 SakrPower Sytes 3.Installation | 3.1 Base and foundation | -The generator with its base fame canbe placed dreety on an horizontal concrete tvor, ‘ut for # permanent installation, itis recommended that a base concrete foundation holds ~ the generator. ; ‘The major functions ofa foundation are ] “Support the weight of the genset “Tsotate the genset vibration fom the surounding structures, Protection against any water flow inthe plant room, “Compensation of any sbnonnality inthe floor 7 ‘The foundation, for more stability is made under the floor limits (Cf. fig. 3.1). The pad is} nade from antivibration materials, and the main block from concrete(cement, sand, ballast, and metal bars). The gesets ase frame shouldbe inside the mein block by tninimm 20cm from each side to avid fissures onthe edge of the main block due to inten ] anttvtacation ditt ie ; fig. 3.1 4 “The foundation ea, bea hve th owe (Cf, 32) bbe ‘genset’s base frame should be inside the main block by minimum 40cm from each side (0 provide the required stability of the genset 1ea esl a ee w Sik Power ye feteapation east fig. 32 In ll cases, the weight of the foundation's main block should be, atleast, 1.5 times the weight of the generator. ‘The depth of the foundation's main block is calculated via the following formula: ) Li L.SxW . 2.2xLxH aC , ‘Where, W=weight ofthe genset (Tone) ‘Density of concrete =2.2 Tone/n® Another solution, when mounting a generator on a flog oF a simple concrete pad, ito use vibration isolators inserted directly between the sub-base aud the foo: 3.2 Cooling and ventilation ‘The main purpose ofthe cooling system isto dissipate the heat away from the engine's ‘eylinder block, and the soundproof containers into the open space. The cooling operation ‘Process consists on a water cicuit between the engine and the radiator. Water takes theSite Power Syste J ‘engine”s heat when if flows into the cylinder block through multiple vertical holes, and. dissipates it away when passing into the radiator. J Precautions should be taken when installing the genset container regarding the airflow. > ‘No obstacle is allowed to exist infront of the engine's cooling fan ata distance not more than three meters, ‘Also, case the genset’s containes is to be installed in a closed local (plant room), the heat | injected by the engine's fan will over-heat the plant room. ‘Ventilation ofthe plant room is necessary fo remove the hea dissipated by the engine, ") alternator, ad its accessries, and to provide combustion at J ‘The air coming fom the engine's fan shouldbe dissipated tothe open space, by ducting it directly outside the plant room, and ereate inlet ducts to the plant room forthe incoming fresh air to reach the engive “The inlet duct to the plant room should be minim 1.5 times the size ofthe radiator air outlet ducting | 3.3 Exhaust system “The exhaust pipe must be vented outside the engine room, oF the plant room, andi no circumstances shoul th exist aes be allowed to daw back the engite root, Sizing “The sizing of an exhaust sytem pipes should take as a first priority the back” ~ pressure in the system, which should never exceed the limit fixed in the engine datasheet) {oormaly around O.1bs), ] ‘The diameter of the exaust pipes is based upon the following parameters “Exhaust gas flow | “Maximum allowable back-pressue “Length of straight pipe “Number of bends ) “Resistance through the silencer “Linear velocity through the silencer \ “The exhaust system in the genset is well calculated, and incase it should be extended fo" any reason, some precautions should be taken ia consideration j “For a distance not more than 5O meter, use pipes havin the same section of thse used for the exhaust systen inside the genset container. 1 “To insure that tte condensation doesnot rin back (othe engine, horizontal pies shuld slope downwards away fiom the engin sree cald ran water or eondensation from remaining inthe exhaust system, dan points] should be made a the base of vertical pipes “Pipes passing tiroush roof, walls, or partitions should be protected with metal sleeves. | and closing plates infilled with mineral wool . |mo Veseeu seers eo ou SatrPower Sy When silencer and part of pipes are tobe installed inthe plant room, they should be fully insulated with Sem of minerl wool and cad with aluminium foi, in order to reduce the heat gain into the plant room, ~The inner radius of 90° bend should be 3 times the diameter ofthe pipe. A long exhaust system may needa terminal silencer to reduce any regenerated noise that ray occur in the pipe afte the primary silencer. Al the termination point, the pipe shouldbe protected from rain, either by turning into the horizontal plane, or by using a rain eap. ~Along the routing, pipes shouldbe fced tothe builing, or a seo structure via enti- vibration holders, and should be minimum 20m away from cement wall or structures to ‘avoid fissure in cement duc tothe exhaust’ heal. Expansion joints must be installed at cach change of direction to compensate the thermal gxowth inthe pipe during operation. Also some flexibles may be requited to absorb the + pipes dilatation due co heat. 3.4 The fuel system ‘The gensets are equipped with an intemal daily fuel tank. If another fuel tank with bigger size is to replace the existing one, i should be installed outside the genset’s canopy and ‘connected to the engine with some precautions regarding the following points: = The feed connection onthe tank should not be so low in arder to maintain the suetion capability ofthe fel pump. The lowest posse fuel Tevel in the fuel tank should not be “ess than Im below the fuel purp inlet. ~ The return connection on the fuel tank should not be higher than the suetion lift capability of the engine's fuel pump. The maximum allowable fuel return infet on the tank should never exceed 30cm above the injectors level ~ Supply and retum fue lines must be capable of withstanding 1Tbars peak pressure and 0.65 bars vacuum. Supply fuel pipes inner diameter must be a least as large asthe transfer pump inlet for lengh of less than 5m, which is 4”, Fora larger distance the pipe size must be increased, Return fuel pipes inner diameter must beat least as large as the return flexible pipes used inside the container, whichis ¥4". For a larger distance the pipe size must be increased, and should never be less than one pipe size smaller than the fuel supply Tine. ~ Never run a fue tira line ducetly back f the engine supply fines. The fuel will over hheat and break down, Aid, for multiple engine installations, each generator must have 2 separate fuel return line, Never add fuel tothe dsity tak while the engine is running,4-Maintenance 4.1 Introduction ‘To ensure matinum reliably and perfomance fom a generating set itl important that all components are inspected periodically, and where necessary, prescribed maintenance caried ou ‘The principle behind an organised maintenance plan is eaying out on regular tt ‘the lst of items that should be checked | 4.2 Routine maintenance j Oil, anti-ftceze and filter replacement is usually determined by the rele} ‘manufacturers, based on accumulated hours run by the engine. J ‘in the case ofthe starter batteries the'replacement date is detected by thei event failure due to their natural life being achieved warning of this is given by regular check: the condition of the electrolyte. 4.3 Maintenance program ) 1t is recommended that the person responsible for the maintenance of the generat parts formulate tineiable, or schedule, of inspection and maintenance, grouping (og {the component atention a ike intervals, a follows: 5 Maintenance Record _ Engine pe. Aerator SN Date | Hours or Time! Oil change] Oil iter] Fuel fiter | Air iter Intervals | | change | change _|__ changeSw een a , Sak Power Ste ‘And these intervals recommended by the engine manufacturer are based on the gens ' room conditions being clean and dry. Other wise they should be carried out moi frequently. “Maintenance program is divided into the following intervals 4.3.1 Daily Maintenance Before you start your engine you should carry out the following checks. 1 Make a visual check ofthe entire genset, Watch for sign of potetial leaks from the engine fuel syste, cooling system or nbncating system ‘The alternator for bstrucions in the cooling sreen ‘The fue! level in the daily fuel (ank integrated in the base fame Coolant level in the radiator. The engine off level “The condition ofthe fan belt and its tension Dispose any unnecessary items in the vicinity of the genset that may inhibit operation o: represent case of potential injury. 8, Drain water/sediments from the fuel-water separator fits ited 9. Clean the air pre-leaner jar and dry-ype air leaner dust pan wen fied 10 Start the machine afterall checks have been made, and check the following 11 The contol panel for indications of abnormal operation 12. For any noise or vibration 13, For fluid leakage or high temperature 4.3.2 Weekly Maintenance ‘Weekly maintenance is more through and involved, and would normally include a test r for stand by operation. It includes the following checkpoints: 1. The level ofthe electrolyte in the battery is!" above the top of the separators. Top with distilled water if necessary Never add. acd Check the batteny is ‘not gassi excessivel 2 The coolant levels and make sur that wo dit of foreign bas was elected in the ducting, louvers or ventilation grills Also check the radiator matrix, add distillate: wat only. 5 3, The alternator and control box for heavy accumulation of dust and dirt, Clean a heavy accumulation as electical hazards, as well as cooling problems could arise, 4, The air filter. Clean or replace it if necessary, 45, Drain water and sediment fiom the fut tank and fuel filters. 6 All hase connections and hose conditions for eaoing and air ication systemsSe Power Sy 17. ‘The most important check i the run test. As you run the generator observe thatthe engine cranks with a good tum of speed, sluggish cranking will indicate thatthe battery is, | jn poor condition. Observe that the plant runs up to speed. Note: in case of diese! engine should never be allowed to run for more than fen minutes 4 running off load. j ‘As the engine unaing keep watch for 30 minutes for any abnonnaites such as a “Moving pars catching ] b Leakage of libriating oi and elo ° Exhaust fumes or coolant @ Black exhaust smoke, | e Check for excessive vibration or nose or smell of eating £ ‘Altenatos frequency, voltage and current on each phase & Gauging voltage should be upto 14 vol for 12-vol system, and 27 vot for 24! & se aystem, Ihe teat is dane top the generator and observe tha the plant tops. > 4.3.3 Monthly Maintenance In the monthly maintenance, test should make a check for the following items: i 1. Drain condenses traps in the exhaust system, if so equipped, and check for exhaust | leakage. 2. Check for items such as starter, batteries, and other components which naturally“) deteriorate progressively with time. 5 3. Check, clean or replace all kind of filters (fuel, oil, water, ec...) 7 4. Load ran fest is taken up to fill working temperature, pressure, voltage, et. } 4.3.4 Yearly Maintenance tue yeasty manennoeinlis repting te reviusaitnance seemed Ts ee ee owing pus | 1. Clean the battery and their terminals (use for cleaning the terminal petroleum je never attempt to use grease). Also check terminals for tightness, F Choose a time when you can isolate the control cubicle (control panel) compris!» jc ‘he supply and the batteries. Open the euble; clean the equipment with vacua fear and a fluff free cloth, Also vacuum out any cable ducts. } Check all nuts, bolts and serews for ihness, and all connections for signs of conosle should be cleaned and given a smear of petroleum jelly. ; Check all parts for cracks and distortion, especially the fuse holders at carers 6 fi lips Close and fasten the door of the cubicle and reconnect the eubicte | »‘Saks Power Sys 3. check and tighten all exhaust connections, electrical connections, and mounting bolts 4, Grease all bearings 5. Check all safety devices by electically simulating « fault fo ensure that all systems function properly inthe event of default 6. Check and adjust the valves and injectors 7. Check the crank ease breather, 8. Change the anticorrosion additive, and check DCA concentration 9, Check all belts conditions 10,Stcam cleaning of the engine. 11.Check crankshaft ends clearance. Also refer to the diesel engine and altemator manufacturers maintenance booklets to ass proper maintenance schedule as illustrated in the table below Reyes previous co =e 2 Teen mousing iis ool he ie 1 Chee nge ol ok te atey este tee + Onesie Sas em Seine far damage ak Ieee ce aye eisai [tes for ensue + Dain water! “sient fl ns Stel ers, 2 Checks ac Gane preseanet aad | ‘ist pou 2 Gis water 2 Chea engine eCheck al bse, ‘Stel anaton tonto ry 40 Fortean sores * Based on eg hours open por dy Also fellow any ether anauictce recommendations for special appaton5.1 Alternator Trouble shooting ‘Trouble Possible Cause Sake Power Syste Trouble shooting Remedy (aye be dene wo the (etineamicheseD we altemator wil nat cenecgize (No load voltage below 10% of rated voltage) ® Tanae connections Rotating Diodes or surge suppessoe broken citation suit Shorted or interrupted, change incase they are ‘open or shor- gang aly dom sal 13H Aagh SG Xe gana cies 7 ctl else esa J ah Aas Al siadl ghyl Guang i il Ul Ge JS Ae apa Gees pe 8 ele Uy badl WIS Jad yl GIG ed Jue lay aeshll dal lly Deal 98h ogy afl HY lal Aaa Lzad sobs UeBlle Cre 40 ce Ub Uphuenis Aft, yeSll Ae gana! weal SS UBL Yl Layee Capp all ea obo A dS Gl pas Qaze Ciao Ltd Yspad ga Abealts Gal, Hell Beall ein» ELA —9 ipa Fe yap Spell LY Go %80 Ayal said Y of cay Uys) ele 100 ds} ~ sleds %50 Ge JB Y te AS HW) cles cigjle cys LIS Olly cy} AE dole 250 dS sie SO, Bae eG A Oy Illy CyM OH A eke (4 Vere doaalwet ats Be Aero ole 9 ARN 8S Gl Lay hd aca £0) J obi Gy Ja cL, aes Ad Le Sel ets al fs CMs SEL jy QE Gas Ae geal tal aca C48 i ye 5 $e Fel 1000 dae — Fels 2500 GY tad Uyoy te — EM gk Las ABS cal 2 raph ind ae JBL oe Ga 09-444888 sats 09-445444 - atsAy SI A ll to yt Be Jot seveeeetpeal bees Be cS es) a pe] pel ae | pe | | oe el weap | eae | en [ev [get coc calic. 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