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User manual 

1

 

General

 

Introduction

 

1.1

 

Brief

 

Introduction

 

HYUNDAI

 

series

 

diesel

 

engine

 

generator

 

sets

 

is

 

the

 

core

 

products

 

of

 

HYUNDAI

 

Power

 

Equipment

 

Manufacturing

 

Co.,Ltd.

 

Thanks

 

to

 

their

 

good

 

performance,

 

the

 

generator

 

sets

 

are

 

widely

 

used

 

in

 

the

 

fields

 

of

 

construction,

 

communication,

 

banking

 

business,

 

mining,

 

leasing

 

industry

 

and

 

other

 

special

 

sites.

 

As

 

what

 

you

 

are

 

expecting,

 

HYUNDAI

 

generator

 

sets

 

endeavor

 

to

 

meet

 

your

 

needs

 

for

 

the

 

concept

 

of

 

individual

 

design

 

through

 

the

 

excellent

 

features

 

of

 

more

 

safe,

 

more

 

reliable

 

and

 

more

 

clean.

 

The

 

generator

 

sets

 

provided

 

by

 

HYUNDAI

 

Power

 

is

 

reliable

 

and

 

professional.

 

The

 

advantage

 

of

 

low

 

noise

 

level,

 

energy

 

conservation,

 

and

 

stable

 

performance

 

has

 

made

 

a

 

credible

 

assurance

 

for

 

many

 

enterprises.

   

Our

 

generator

 

sets

 

supply

 

the

 

following

 

power

 

service:

 

Continuous

 

service

     

Used

 

as

 

main

 

power

 

supply

 

to

 

generate

 

electricity

 

for

 

several

 

purposes:

 

motion

 

force,

 

lighting,

 

heating

 

etc.

 

The

 

generator

 

sets

 

can

 

continue

 

running

 

and

 

allow

 

10%

 

over

 

load

 

for

 

1

 

hour

 

per

 

12

 

hours

 

under

 

variable

 

load,

 

which

 

is

 

used

 

for

 

remote

 

area.

 

Standby

 

service

     

Used

 

as

 

standby

 

power

 

supply

 

to

 

provide

 

continue

 

electric

 

power

 

for

 

non

invariable

 

loads.

 

The

 

generator

 

set

 

is

 

suitable

 

for

 

the

 

area

 

where

 

must

 

ensure

 

continue

 

power

 

supply,

 

such

 

as

 

hospitals,

 

industrial

 

facilities,

 

airports

 

etc.

 

Keep

 

the

 

generator

 

set

 

standby

 

state

 

at

 

any

 

time

 

and

 

start

 

to

 

run

 

when

 

the

 

mains

 

supply

 

is

 

abnormal.

 

Emergency

 

service

 

   

Used

 

as

 

auxiliary

 

power

 

supply

 

to

 

solve

 

energy

 

interruptions

 

that

 

may

 

cause

 

serious

 

problems

 

to

 

people,

 

physical

 

and

 

/or

 

financial

 

damage

 

or

 

to

 

face

 

consumption

 

peaks.

 

The

 

generator

 

set

 

can

 

start

 

in

 

short

 

order

 

to

 

provide

 

steady

 

electric

 

power

 

for

 

the

 

loads

 

when

 

the

 

mains

 

supply

 

happen

 

abnormity,

 

and

 

switch

 

to

 

stop

 

after

 

the

 

mains

 

supply

 

becomes

 

normal.

 

Generally

 

the

 

generator

 

set

 

continues

 

working

 

for

 

several

 

hours.

 

1.2

 

Generator

 

Set

 

Main

 

Parts

 

Specifications

 

NO

           

NAME

 

1

CONTROL PANEL 

2

BUSBAR PANEL 

3

LIFTING LUG 

4

BASEFRAME FUEL TANK 

5

ENGINE 

6

BATTERY 

7

RADIATOR 

8

ALTERNATOR 

9

FUEL DRAIN OUTLET 

10       FUEL LEVEL SENSOR\ 

11              ABSORBER 

1.3

 

Diesel

 

Engine

 

According

 

to

 

different

 

output

 

power

 

of

 

the

 

generator

 

sets,

 

and

 

combine

 

with

 

the

 

advantage

 

of

 

each

 

model

 

of

 

diesel

 

engine

 

in

 

a

 

specific

 

range

 

of

 

power

 

output,

 

HYUNDAI

 

Power

 

chooses

 

the

 

engines

 

with

 

first

 

class

 

performance

 

and

 

high

 

reliability.

 

And

 

furthermore,

 

HYUNDAI

 

Power

 

pay

 

special

 

attention

 

to

 

the

 

Summary of Contents for DHY34KSE

Page 1: ... REGULATION STARTING METHOD DISPLACEMENT cc OIL CAPACITY L ALTERNATOR RATED POWER kW kVA POWER FACTOR Cosφ VOLTAGE REGULATION LOW OIL PRESSURE BLOCK ON START UP LOW BATTERY HIGH TEMPERATURE ON WATER LOW OIL LEVEL LOW RUNNING ON ENGINE EMERGENCY STOP N G kg G W kg PRODUCT DIMENSIONS mm CAPACITY units container 25 31 28 34 50 230 400 45 IL NT MRS 10 INCLUDED 1x12v 60Ah 93 10 5 2 9 3 18 10 68 HY4102 ...

Page 2: ...DIESEL GENERATOR Models Hyundai Engine Series Operation and Maintenance manual ...

Page 3: ...tock and property Some or all of the following PPE warning signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so may result in personal injury Warning Signs and Symbols FOLLOW safety messages to avoid or reduce risk of injury or death DANGER indicates a hazard which if not avoided could result in serious injury or death WARNING indicates a haza...

Page 4: ...e even if doors and windows are open If you think you or someone around you has been affected by carbon monoxide poisoning Leave the affected area and get fresh air immediately Open doors and windows and turn the machine off See your doctor immediately or go to hospital let them know that you suspect carbon monoxide poisoning DO NOT use in an enclosed area or a moving vehicle General fuel safety C...

Page 5: ...rior to carrying out any maintenance work Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage you should stop using the equipment The damaged item must repaired by an electrically compe...

Page 6: ... starting DO NOT pour water directly over the generator nor wash it with water For each use make sure that the generator has been electrically grounded earthed Failure to do so can be fatal DO NOT smoke while charging a battery The battery emits flammable hydrogen gas which can explode if exposed to electric arcing or open flame Keep the area well ventilated and keep open flames sparks away when c...

Page 7: ...is close to the battery and fuel because the mixture of volatilization from fuel and hydrogen generated by battery charging process will cause explosion when it meets sparkle or naked flame The generator set installation room shall be facilitated with BC and ABC fire extinguisher and operators shall be familiar with the knowledge on how to use it When fan protection cover or other protection cover...

Page 8: ...t is running do not attempt to reach under or around the guards to do maintenance or for any other reason Keep hands arms long hair loose clothing and jewelers away from pulleys belts and other moving parts SAFEGUARD WARNING Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105 dB A Prolonged exposure to noise levels above 85 dB A is haza...

Page 9: ...nal disconnected prior to attempting to connect or disconnect load connections Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground Make sure connect generator set to earth Replace the generating set terminal box cover as soon as connection or disconnection of the load cables is complete Do not operate the generating set without the cover secur...

Page 10: ...erator Set Working Room 4 2 5 Installation of Generator Set 5 2 6 Cooling system 7 2 7 Lubricant system 8 2 8 Fuel system 8 2 9 Battery 10 2 10 Electrical Connection 11 2 11 Power distribution system 11 3 Operation 3 1 Inspect Before Operation 12 3 2 Generator set s running 12 3 3 After Running 13 3 4 Record for running 13 3 5 Matters need attention 13 3 6 Operation for control system 14 3 7 ATS c...

Page 11: ...tandby power supply to provide continue electric power for non invariable loads The generator set is suitable for the area where must ensure continue power supply such as hospitals industrial facilities airports etc Keep the generator set standby state at any time and start to run when the mains supply is abnormal Emergency service Used as auxiliary power supply to solve energy interruptions that ...

Page 12: ...a pusher fan and thermostat The alternator has its own internal fan to cool the alternator components 1 6 Electrical System The engine electrical system is 12 volt or 24 volts DC negative ground earth This system includes an electric engine starter a battery and a battery charging alternator For DC 12 volts electrical system one battery is given For 24 volt system two lead acid batteries are given...

Page 13: ...ilitated onnect direc valve is an UNDAI Pow n for the rplus lubrica t by openin ransportatio been designe Standard ca fting hole o enerator set canopy roo me which b o have stati the generato Optional S ed with heat l the pre hea n be started gency cases 3 y with ctly to nother wer It users ant or g the on ed for anopy on the ts we of and better ionary or set Spare ter for ater is under s and al d...

Page 14: ...nect to other architecture s foundation The width and depth of foundation shall meet requirement Ensure foundation s levelness and smoothness If possible waste discharge sink can be sued so that the waste oil can be discharged in a timely manner Cable channel for generator power output cable need to be reserved Normally concrete foundation is reliable simple and preferable When pouring the concret...

Page 15: ...set to outside For example corrugated vibration reduction pipe has been used to connect exhaust pipes air exhaust path fuel inlet pipe fuel return pipe and busbar cable etc all of these parts need to use soft connections Only in this way we can reduce the adverse effect caused by the vibration of generator set to the minimum extent 2 5 2 Ventilation When a generator set with a complete set of radi...

Page 16: ...essure and side stress Reserve some space for hot shrinkage and cold expansion Reserve space for generator set vibration Reduce exhaust noise level Overload of exhaust backpressure will cause following adverse effect Output power loss Fuel efficiency reduce Exhaust gas temperature rise Note When more than one generator set are installed try not to discharge all of the generator sets gas from one e...

Page 17: ... the liquids in a separate container evenly and then add the mixture into the radiator ensure the anti freeze will not freeze under low temperature In the area when there is low possibility of freezing the coolant can be a mixture of water and anti rust according to the anti rust which recommended by the engine supplier and refer to its operation manual mix the liquids in a separate container even...

Page 18: ... specification as that existing in the radiator For some generator sets installed with coolant filter please open the filter s valve before put into use 2 7 Lubricant system Lubricant system is composed of oil pan oil pump strainer oil pipe oil cooling unit oil filter unit and the oil path inside of the engine and all kinds of lubricant parts which are in relative motion etc The main purpose of th...

Page 19: ...tor sets provide base frame style fuel tank for customer The base frame style fuel tank is installed with fuel tank fuel pipes and fuel level indicator This fuel supply system does not need customer to make other installations Customers only need to add fuel to the base frame Users who intend to self manufacture the fuel tank shall use stainless steel or steel plate to make the backup tank do not ...

Page 20: ...s are required to correctly connect the signal line to this control panel details see the control panel operation manual Automatic transfer panel optional is the automatic transfer switch for transfer between generator set and mains details refer to control panel operation manual 2 9 Battery Our generator set standard configuration provides start battery as accessory parts According to user s diff...

Page 21: ...must be connected to an earth ground Since the set is mounted on vibration isolators the ground connection must be flexible to avoid possible breakage due to vibration Ground connection cables or straps should have at least full load current carrying capacity and meet applicable regulations 2 10 3 Insulation Test Before starting the generating set after installation test the insulation resistance ...

Page 22: ...Start Part of the generator set control panel has been furnished with idle speed full speed transfer switch users can choose if the engine need to be started in idle speed or in one time full speed Usually the time period for idle speed shall not exceed five minutes Do not run the generator set in idle speed in a long time period Press on the start button the duration shall not exceed 30 seconds e...

Page 23: ...ning situation and if there is any malfunction warning generator set shut down etc Only when the correct and complete record for running maintenance has been kept very well the user can get correct and excellent after sales warranty service 3 5 Matters need attention Warning When engine s temperature is very low the time period for idle speed shall be properly extended However when the generator s...

Page 24: ...s number 3 times the Alarm LCD would flash If you need to restart wait at least 30 seconds before the retry 8 Check the reading of Voltage Meter and Frequency Meter by operating the Voltmeter Change Over Switch Once the generator set is running at the correct voltage and frequency Turn the Generator set main circuit breaker to ON 9 Turn on every switch or circuit breaker of loads from heavy to lig...

Page 25: ...light means AMF controller is active then user can select operation type OFF MAN AUTO MEASUREMENT A OFF mode Start stop mains power on off generator set power on off is inactive in this mode B MAN mode 1 Press start pushbutton to start engine 2 When output voltage is in the set range a Press mains power on off pushbutton to turn on the switch b Press mains power on off pushbutton the switch will b...

Page 26: ... if generator set is used for self start standby power In order to achieve full automatic transfer between mains power and generator set power to guarantee all load present our ATS panel select the best ATS for all generator set And to the most possibility to serve our customers demand we prepare two types of ATS MRS and AMF Besides MRS and AMF can be jointed to a double standby ATS after a little...

Page 27: ...TO that is OK detail operate step refer module control system ATS PANEL introduction No MODEL 1 ATS switch 2 panel lock 3 mains power output hole 4 generator power output hole 5 communicate with generator module port 6 load power cable output 7 panel on ground leg Maintenance inspect or exchange parts attention Attention All operator must be professional electrician Turn switch on OFF position mak...

Page 28: ... battery For each 50 600 hours of running or at least each 12 months Change lubricant and lubricant filter Because the quality of lubricant oil sulfur content of the fuel and lubricant consumption rate of each engine is different the interval for lubricant oil change for each generator set will be different When change the lubricant oil at the same time oil filter needs to be changed otherwise the...

Page 29: ... refer to Control Panel Operation Manual for details 4 5 Start battery Batteries which have been stored in a long time shall be properly charged before being used so that to ensure normal capacitance of the battery Densimeter can be used to check the actual capacitance of the battery Normal operation and battery charging will cause some water inside of the battery being vaporized And therefore con...

Page 30: ...liminate the malfunction s Especially important for new generator set s customer One thing must to be emphasized most of the malfunctions are caused by user s improper installation operation and maintenance Users are entitled to doubt that the malfunction s is caused by the generator set s manufacture failure but this conclusion shall be based on correct installation operation and periodically mai...

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Page 39: ...APPENDIX E 1 ...

Page 40: ...2 ...

Page 41: ...3 ...

Page 42: ...t running record TIME ENGINE PARAMETER GENERATOR PARAMETER IF RECORD FOR MALFUNCTION IS AVAILABLE OPERATOR REMARK Start stop generator set time Accumulated running time Oil pressure Temperature Voltage Current Frequency Power ...

Page 43: ...t serial No Engine serial No Alternator serial No Accumulated running hours Maintenance cycle Reasons for maintenance periodic maintenance or malfunction maintenance Inspection and repair Inspection and adjustment Change of parts Clean and maintenance Others Conclusion for maintenance Maintenance staff signature ...

Page 44: ...APPENDIX H ...

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